This issue of SITRA NEWScovers the following topics:
Page no.PRODUCTIVITY AND COSTS
Quality Assurance in spinning mills – a case study 1
TECHNICAL NOTES
Influence of yarn friction on knittability of cottonyarns 5
PROJECTS
Inter-relationships between Deviation Rate inyarn mass (DR%) and variations in yarn tensilecharacteristics 7
MEDICAL TEXTILES - Series 19 10
CONSULTANCY SERVICES OFFERED BY SITRADURING JANUARY – FEBRUARY 2013 12
STAFF NEWS 13
TRAINING PROGRAMMES 16
ABSTRACT OF A TECHNICAL ARTICLE 17
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SITRA News
Quality Assurance in spinning mills – a case study
Quality control is the watchword in the competitive industry like textilesas it affects the user need as well as profitability. It (QC) is generallya procedure or set of procedures intended to ensure that a manufacturedproduct or a performed service adheres to a defined set of qualitycriteria or meets the requirements of the client or customer. Thoughall spinning mills are having a quality control department, nevertheless,in most cases, the activities of QC need to be enhanced with asystematic approach in meeting the quality requirements of a product.This process is known as Quality Assurance (QA).
QA is the systematic measurement in comparison with a standard,monitoring of processes and an associated feedback loop that conferserror prevention. Two principles are included in QA: “Fit for purpose”,the product should be suitable for the intended purpose and “Rightfirst time”, mistakes should be eliminated.
Of late, the importance of “QA” has been picking-up in spinning mills.Many mills, more particularly those are largely in export which business/ having a group of mills, have a QA department in the place of QCdepartment.
To highlight the activities of QA in spinning mills, a typical example isgiven in this note as case study.
Quality Assurance in a spinning mill – a case study
The activities/functions of Quality Assurance department of a textilemill, having its spinning units working in different places, are givenbelow:
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SITRA News
Organisation structure
All the units are having their own testing laboratories with a range oftesting equipment like Uster HVI Spectrum, Uster AFIS Pro2,computerised count balance, Uster Tester 5, Uster Tensorapid 3, UsterTensojet 4, Uster Zweigle Hairiness tester, etc.
Each unit has a Quality Assurance manager with required supportingstaff including lab assistants. The QA managers of individual unitsreport to the QA manager of the Central Office.
Activities/functions of individual units’ QA department
- Testing of raw material, inter-mediate products and finalproducts.
- Conducting various process control studies
- Ensuring that testing instruments are calibrated as perschedules.
- Analysing customer complaints and replying to the customerswithin a specified time.
- Acting or assisting as management representative for theimplementation of Quality Management System ISO 9001,Environmental Management System (ISO 14001),Occupational Health and Safety Management System(OHSAS 18001), etc.
- Analysing causes for abnormality, etc.
Central QA department
Some of the unique features of the Central QA department arementioned below:
1. All the test results from the individual units are directly uploadedto QA server from the testing instruments. Once the authorizedperson in the respective units approves the test results, thesame can be monitored by the Central QA department. Thishelps to check/compare the quality parameters of the differentunits.
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SITRA News
2. Customer complaints are also uploaded in a separate system,provided for effective handling of customer feedback. If a replyhas not been sent to the customer within a prescribed time, areminder message will be sent to all the persons concerned(Marketing/Production/QA) by marking a copy to the topmanagement.
3. Based on the requirement of QA/marketing department, thesoftware and servers for handling test results and customerfeedback are created, maintained and updated by the mill’sown EDP team.
The following are the main activities of the Central QA departmentother than the routine schedules.
1. To review periodically the testing schedules, activities andprocedures between units for standardisation.
2. To co-ordinate with marketing department while finalising theorder regarding technical specifications.
3. To prepare standards for all in-process testing with controland alarming limits, which are reviewed periodically and revisedwhenever necessary.
4. To prepare quality standards for end product and get approvalfrom the top management.
5. To conduct round test between the units at regular intervalsfor ensuring the correct working of various testing equipment.
6. To share information regarding the trials conducted in therespective units with the other units.
7. To assist in developing new products.
8. To co-ordinate with other departments such as Production,Engineering, Maintenance, Human Resource, etc., andorganise management review meeting, group technicalmeeting, etc.
9. To organise internal and external audits for implementation ofsystems such as ISO 9001, ISO 14001, OHSAS 18001, etc.
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SITRA News
Customer feedbacks handling procedure
The mill has fixed a time frame for addressing the customer feedback.The units concerned should send the feedback to the marketingdepartment with a detailed analysis report within 96 hours. In general,the feedback should be addressed to the customer within a span of 7days. Otherwise, a reminder message will be forwarded to all thepersons concerned (Marketing/Production/QA) by marking a copy tothe top management.
The following flowchart explains about the procedure of handling thecustomer feedback.
Feedback from customer to marketing department
Immediate acknowledgement by themarketing department to the customer
Forwarding the customer message/samples to QAD of the
respective units
Circulate the complaint to all the concerned persons in the unit by
the QA manager
Aanalyse the feedback based on standard procedure/checkpoints
Based on the customer priority, nature of
complaint, etc. make a visit to the customer
A
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SITRA News
Flowchart Addressing customer complaints
- Liaison and Consultation division
Influence of yarn friction on knittability of cotton yarns
Yarn friction contributes to difficulties during knitting in two ways –firstly, it affects the tension of the yarn supplied to the knitting elementsand secondly, a high friction may increase the abrasion of yarn withknitting elements and guides. Tension in knitting is one of the factorscontrolling the amount of yarn placed round the needles (length ofyarn per stitch) and therefore, it affects the length of knitted goods.The final tension under which the yarn is laid round the needles dependson the take-off tension from the package and the friction at all points ofcontact of the yarn i.e., guides, tensioning devices, needles, etc.
Detailed reply should be forwarded to the marketing department by the respective unit’s QA department
Review the various feedbacks in the periodical meetings at Central
Office
Monitor the effectiveness ofpreventive action in the subsequent lots
Suitable reply will be sent to the customer
by the marketing department
A
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SITRA News
As per studies conducted at SITRA and elsewhere, the increase inyarn tension is significantly influenced by the co-efficient of dynamicfriction (µ) of yarn with metal surfaces. The increase in tension forvarious yarn µ values after passing over guides are given in Table 1.
Table 1 Increase in tension for various µ values afterpassing over different number of guides
It is important that the co-efficient of friction should be low and uniform.A sudden increase in take-off tension may produce a break in theyarn, and a “press off” will be the result. Also, small changes of tensionfor a short duration may produce differences in loop length.
As per available literature, the variations in the length of yarn in theloop and the total length of knitted goods are often due to the differencesin yarn tension, which depends on the friction between the yarn andobjects with which the yarn comes into contact. The results of a studyconducted at SITRA in this connection are shown in Figure 1.
Figure 1 Relationship between yarn tensionand yarn length per 1000 stitches
µ Factor by which tension increases1 guide 2 guides 3 guides 4 guides
0.15 1.3 1.6 2.0 2.60.25 1.5 2.2 3.2 4.8 0.35 1.0 3.0 5.2 9.10.65 2.8 7.7 21.0 59.0 0.90 >4.0 >17.0 >69.0 >286.0
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SITRA News
In order to reduce the excessive tension generated during knitting, theco-efficient of dynamic friction (µ) requires to be maintained between0.15 to 0.17. Hence, waxing during cone winding is popular for knittingyarns. For better performance, the wax pick-up during winding may bemaintained in the region of 0.15% so that µ can be maintainedwithin the required limits.
- Dr.K.P.Chellamani,Spinning division
Inter-relationships between Deviation Rate in yarn mass(DR%) and variations in yarn tensile characteristics.
An uneven yarn gives rise to a patchy fabric. Very high levels ofunevenness also results in loss of yarn strength.
In the recent past, a new parameter called “Deviation Rate (DR %)” isintroduced as a quality criterion in yarns to be measured and monitored.DR is defined as the ratio of the length of yarn, which has massexceeding pre-set mass limit to a given cut length of yarn.
DR is a sort of medium term variation in spun yarns. Earlier SITRA hadconducted some studies on the effect of fibre properties and processvariables on deviation rate in yarn mass. Studies pertaining to theinfluence of yarn mass variation on tensile property variations arescanty in literature.
Hence, SITRA has conducted a study to evaluate the extent ofrelationship between deviation rate (DR %) and variations in yarntensile characteristics. Single yarn strength CV %, single yarnelongation CV % and weak spots in the yarn were taken as theparameters that broadly represent the tensile property variations inthe spun yarn, in the study.
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SITRA News
Materials and methods
51 yarn samples differing widely in their deviation rate values(DR%) in the count range of 20s to 100s were collected from themember mills. These samples were tested for single yarn strengthCV %, single yarn elongation CV % and the number of weak spots ina given length of yarn.
In the present study, weak spot has been defined as “Spots in the yarnwith breaking strength value lower than 70 % of the average breakingstrength of the yarn”.
To assess the presence of weak spots, 5000 m of yarn has beentaken as the sample length. Since weak spot is a rare occurrence,testing a longer length of yarn is essential to arrive at a realisticestimate. An expression connecting deviation rate in yarn mass withyarn strength CV %, elongation CV % and weak spots in yarn hasbeen developed.
Prediction expression connecting deviation rate in yarn massand variations in tensile characteristics.
Theoretically, one would expect a good association between variationin yarn mass and variations in tensile characteristics. The followinglinear expression has been arrived at in this connection.
DR% = (3.5 x strength CV %) – (1.8 x elongation CV %) – (0.1x No. of weak spots / 5000 m) + 10
…………….. (i)
The strength CV %, elongation CV % and weak spots in the yarn weremeasured using Tensojet tensile testing instrument. The advantage ofusing Tensojet instrument is that it directly provides information on theextent of weak spots in the yarn. Moreover, testing speed in the Tensojetis high at 400 m/ min which facilitates testing of longer lengths ofyarn in a relatively shorter period of time.
The predicted values give a very close fit with actual deviation rateresulting in a high correlation of 0.91 (Figure 1).
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SITRA News
Figure 1 Relationship between actual DR% and predicted DR%
For the benefit of the mills who do not have the Tensojet equipment,the yarn quality attributes were also evaluated using Tensorapidinstrument and a prediction expression has been derived at.
DR% = (3.3 x strength CV %) – (2 x elongation CV %) – (0.1x No. of weak spots / 5000 m) + 19
…………….. (ii)
The values predicted from the above expression also showed a goodcorrelation of 0.89 with the error of estimate at 2 DR %.
Effect of cone winding on DR %
In view of the fact that majority of the mills are using automatic conewinding with stringent clearing of their yarns, it is of interest to knowwhat happens to the deviation rate in the ring yarns after cone winding.Hence, the ring yarns and the corresponding cone yarns, collectedfrom the member mills, were tested for the deviation rate and the valuesare given in Table 1.
Average error of estimate = 1 DR%
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SITRA News
Table 1 Deviation rate in cop yarns and the correspondingcone yarns
Due to cone winding, the deviation rate in the yarn mass generallycomes down which is attributed to the removal of objectionable yarnfaults in winding. The extent of reduction in the deviation rate after thecone winding, on an average, is around 1.5 DR% (absolute values).The difference in the quantum of reduction in DR % between countsmay be due to the differences in fault clearer settings maintained bythe mills for different counts.
- K.P.Chellamani, D.Veerasubramanian & M.K.Vittopa,Spinning division
Wound dressings and their application areas
The major properties of some wound dressings in the market and theirapplication areas are given in Table 1.
Table 1 Types of wound dressings and their application area0s
S. No.
Yarn count
Deviation rate (DR %)
Ring yarn (A)
Cone yarn (B)
Difference (A – B) (absolute values)
1 20s K 30.40 28.80 1.60
2 30s C 22.67 21.56 1.11
3 40s C 25.25 1.25
4 60s C 22.92 21.62 1.30
5 80s C 20.70 18.90 1.80
6 100s C 21.67 20.00 1.67
MEDICAL TEXTILES Series 19
Wound dressing type Application areas & other relevant particulars
Gauze • Dressings can stick to the wound surface and
disturb the wound bed when removed • Used for minor wounds or as secondary dressings
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SITRA News
Table 1 (contd..)Wound dressing type Application areas & other relevant particulars
Tulle • Dressing does not stick to wound surface • Suitable for flat, shallow wound and for patients
with sensitive skin
Semi permeable film
• Sterile sheet of polyurethane coated with acrylic adhesive
• Transparent allowing wound checks • Suitable for shallow wound with low exudates
Hydrocolloids
• Composed of carboxymethyl cellulose, gelatin, pectin, elastomers and adhesives that turn into a gel when exudates are absorbed. This creates a warm, moist environment that promotes debridement and faster healing
• Can be used in wounds with light to heavy exudates, sloughing or granulating wounds
• Available as adhesive or non-adhesive pad, paste powder and self - adhesive pads
Hydrogels • Composed mainly of water in a complex network
of fibres that keep the polymer gel intact. Water is released to keep the wound moist
• Used for necrotic or sloughy wound beds
Alginates
• Composed of calcium alginate (a seaweed component). When in contact with wound, calcium in the dressing is exchanged with sodium from wound fluid and this turns dressing into a gel that maintains a moist wound environment.
• Used for exudating wounds, debridement of sloughing wounds, low exudating wounds etc.
Polyurethane or silicone foams
• Designed to absorb large amounts of exudates
Collagens
• Dressings come in pads, gels or particles • Promote the deposit of newly formed collagen in
the wound bed. Absorb exudates and provide a moist environment
Foams • Absorb large volume of exudates from discharging
wounds • Help to reduce the frequency of dressing changes.
Atraumatic dressings • Reduced adherence to a drying wound • Can be removed without causing trauma to the
wound and surrounding skin
Soft silicone dressings
• Dressing coated with soft silicone as an adhesive or a wound contact layer
• Suitable for almost all indications where it is important to prevent trauma to the wound and the surrounding skin
Composite wound dressings
• Combine the properties of hydrocolloids and polyurethane foams, making the dressing easy to apply and remove and last longer than any of these products used alone.
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SITRA News7
Different types of wounds and the different stages of healing the woundrequire different dressings or combinations of dressings. Table 2 showssuitable dressings for different wound types.
Table 2 Suitable dressings for different wound types
To be continued…- K.P.Chellamani and M.K.Vittopa,
Spinning division
MEDICAL TEXTILES - 11 S.no. Type of study No. of mills
Consultancy services offered by SITRAduring January - February 2013
1. Techno-economic viability study 12. Powerloom machinery inspection for district
industries centre 13. Energy audit 2
Besides the above major consultancy studies, SITRA also offeredsolutions to four adhoc problems in the area of spinning process.Thirty nine instruments were calibrated, 1 instrument was certifiedand 232 accessory samples were tested.
Wound type Dressing type
Clean, medium-to-high exudates (epithelialising)
• Paraffin gauze • Knitted primary dressing
Clean, dry, low exudates (epithelialising)
• Perforated plastic film-faced dressing • Vapour -permeable adhesive film dressing
Clean, exudating (granulating) • Hydrocolloids • Foams • Alginates
Slough-covered • Hydrocolloids • Hydrogels
Dry, necrotic • Hydrocolloids • Hydrogels
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SITRA News
Meetings attended
Dr. Prakash Vasudevan, Director, attended the following meetings,
- the appraisal & review of Technology Mission on TechnicalTextiles (TMTT) by M/s.Investment information Credit RatingAgency (ICRA) Management consulting services, held at Officeof the Textile Commissioner, Mumbai, on 4th January 2013.
- the BIS meeting, held at BIS Manak Bhavan, New Delhi, on16th January 2013.
- the meeting of the Standing Council for Market Access Agreement(SCMAA) under the Chairmanship of Shri V.Srinivas, JointSecretary (Exports), held at Udyog Bhavan, New Delhi, on 17thJanuary 2013.
- the 6th meeting of Project Monitoring & Approval Committee(PAMC) under Research & Development Scheme of Ministry ofTextiles, held at Office of the Textile Commissioner, Mumbai, on28th January 2013.
- the 4th meeting of Project Monitoring & Approval Committee(PAMC) to consider R & D projects, held at Udyog Bhavan, NewDelhi, on 26th February 2013.
Dr. K.P.Chellamani, General Manager - Projects, attended the 18thpurchase committee meeting of “COE-Indutech” held at PSG Collegeof Technology, Coimbatore on 22nd February 2013.
Dr. K.Sajjan Rao, Research Associate & Head of Training divisionattended the meeting of the empowered Committee on Integrated SkillDevelopment Scheme (ISDS) held under the chairmanship of Secretary(Textiles) to take stock of the progress made by Implementing Agencies
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SITRA News
(IAs) under component - I of the scheme.
Papers published
1. K.P.Chellamani and R.S.Vignesh Balaji “Medical textiles usingnonwoven Technology”, SITRA E-Bulletin, January 2013, 1 (1).
2. J.Sreenivasan, P.Subash and D.Shanmuganandam “No loadpower measurement in motors in spinning mills - case studies”,Asian Textile Journal, February 2013, 22 (2).
3. D.Shanmuganandam, P.Subash and J.Sreenivasan “Towardszero burnouts in motors in spinning mills”, The Indian Textile Journal,February 2013, CXXIII (5).
Papers presented / Lectures given
List of papers presented at 54th Joint Technological Conference heldat Ahmedabad Textile Research Association, Ahmedabad on 9thJanuary 2013:
1. Study of failure in electronic circuits of textile machine controls andinstruments - S.Sugumar, G.Chandrasekaran.
2. Interrelationships between deviation rate in yarn mass (DR%) andother tensile characteristics & fabric appearance - K.P.Chellamani,M.K.Vittopa & D.Veerasubramanian.
3. Towards zero burnouts in motors in spinning mills -D.Shanmuganandam, P.Subash & J.Sreenivasan
Dr. K.P.Chellamani, General Manager - Projects, delivered the followinglectures:
“Emerging trends in textile industry” for the senior staff of M/s.Super Spinning group of mills, Hindupur on 29th January, 2013.
“Application possibilities of nano technology & plasma technologyin textiles” for the senior staff of M/s. Super Spinning Mills,
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SITRA News
Coimbatore on 12th February, 2013.
Mr. Sakthivel Perumalsamy, Head - Centre of Excellence for MedicalTextiles, delivered the following lectures:
“Medical textiles - promising past and prosperous future”, at IndianMedical Devices Industry (IMDI) conference held at Ahmedabad on9th January, 2013.
“Medical textile standards” at IMDI conference held at Ahmedabadon 10th January, 2013.
“Medical textiles - an investment proposition”, at Rotary Clubs ofCoimbatore East & Downtown on 19th February, 2013.
Visits
Dr. Prakash Vasudevan, Director, visited the Technotex 2013, held atInternational Trade Promotion Organisation (ITPO), Pragati Maidan,New Delhi, on 17th January 2013.
Mr. K.Balasubramaniyan, Assistant Director, made visits to thefollowing places:
- Naval Science and Technology Laboratory (NSTL),Visakapattinam, Andhra Pradesh - DRDO Lab, for thedevelopment of a new winding technology for winding 0.60 mmmono optical fibre cable.
- Sidd Life Sciences, Chennai for the development of a new weavingmachine for weaving hallow fibre matt for membrane oxygenator.
- DIMA products, Vapi, Gujarat State to observe the functioning ofthe sanitory napkin manufacturing machinery for CoE - Meditech.
Mr. Sakthivel Perumalsamy, Head - Centre of Excellence for MedicalTextiles, visited the Vibrant Gujarat Expo, held at Ahmedabad on 8thJanuary, 2013.
Jan. - Feb. 2013
SITRA News9
Seminar on “Energy Conservation in Industries”
SITRA organised a seminar on “Energy Conservation in Industries” on7th February 2013 at SITRA premises. A total of 190 participants fromtextile mills and other industries attended the programme.
In-house Supervisory Development Programme
At the request of a member mill, SITRA conducted an in-housesupervisory development programme during January 29 - 31, 2013. Theprogramme covered technical topics like labour and machineproductivity, yarn realisation and waste control, quality management inspinning, process control in spinning, energy conservation, TQM andmaintenance practices to be followed and right work methods foroperatives. The programme was well received by the participants,totalling 22.
Pre-employment training and retraining programmes fortextile workers
One out-station mill availed SITRA’s training services for their workers.In all, 20 opertives were trained in 2 batches for the tenting jobs in ringspinning and auto cone winding. The training programmes wereconducted in Kannada.
INTEGRATED SKILL DEVELOPMENT SCHEME (SITRA – ISDS)
The “Integrated Skill Development Scheme” initiated by the Ministry ofTextiles, Govt. of India, aims to leverage the strength of institutionslike SITRA to augment the skill resources of the industry for enhancingcapabilities for skill development. Under this scheme, SITRA is offering13 different skill development programmes. Following are the detailsof the programmes that were conducted during Jan. - Feb. 2013.
HOKTRAINING
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SITRA News
Seventeen outstation and seven local mills availed for training theiroperatives. Totally, 586 operatives were trained in 29 batches in spinningmills for a period of one month for the tenting jobs in preparatory,spinning, manual cone winding, reeling and open end spinning. Thetraining programmes were conducted in Tamil in 10 mills, Kannada in1 mill, Malayalam in 6 mills and Hindi in two mills.
A NEW METHOD OF YARN HAIRINESS REDUCTION BYAIR SUCTION DURING CARDINGMajid Mirzaei, Ali Akbar Gharehaghaji and MohammadZarrebini, Textile Research Journal, December 2012, Vol 82,No 20, pp 2128-2012.
Yarn hairiness is generally characterized by the extent of fibresprotruding from the main body of a yarn. A new method for the reductionof yarn hairiness is presented in this article. The method deals withattaching a simple effective air suction system to the web detachingzone of a conventional carding machine immediately behind crushingrollers. A pair of grooved rollers was also placed between the crushingrollers & calendar rollers over the web. The slivers produced using thenew method was reported to be almost free from dust or short loosefibers. Yarn properties such as hairiness, tenacity, elongation at breakand evenness were evaluated. The ring-spun yarn produced using thenew method was termed as Vacuum Cleaned Carded (VCC) yarn, dueto the removal of the short fibers by air suction. Four types of VCCyarns (yarn A, yarn B, yarn C and yarn D) were produced with variousair suction pressures and grooved roller status. The spinning conditionsmaintained in producing the various yarn samples are given Table 1.
Properties of VCC yarns were compared with those of conventionallyproduced reference yarn samples (Yarn E). The results showed thatthe VCC yarn B is superior in all the major quality attributes. Thehairiness of optimum VCC yarn is lower by approximately 20%, whileits tenacity, elongation at break and evenness were significantly better.
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SITRA News
VCC yarn B also exhibited better spinning stability than the referenceyarn.
Table 1 Spinning conditions maintained
* Spun using a slotted stationary tube instead of designed airsuction unit.
- R.S.Vignesh BalajiSpinning division
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Online survey of raw material cost and yarn selling price (Monthly survey)
SITRA launches a unique “Online survey of raw materialcost and yarn selling price” from April 2013
Salient features of the survey
• This “Online survey” is the first-of-its kind from SITRA
••••• It will cover mill-wise and count-wise yarn selling price (YSP)and corresponding raw material cost (RMC) (Clean material)as well as yarn quality. Each participant mill can submit these
Yarn code Air suction pressure (Pa) Grooved roller status A 441 Rotating B 667 Rotating C 667 Stationary D 667 Stationary (slot)*
E No air suction Reference yarn
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SITRA News
data for up to 10 counts.
• The survey report (in pdf) will be uploaded in the web portalbefore 21st of every month, which can be viewed at any time.The past reports can also be viewed at any time.
• It would enable a participant mill to compare its RMC, YSP, Netout-put value (NOV) as well as yarn quality with other millsevery month.
• Trend in the movement of YSP and RMC between months (forpopular counts) will be highlighted every month.
• Data entry is made very simple. It will take only 15-20 minutesto enter one month data, that too any time during the 1st to 7th
of every month.
• In due course, the online survey will cover some other costsand operational parameters like raw material quality, capacityutilisation, count-wise conversion cost, etc.
• The identity of the participant mills will be kept confidential.
A nominal fee will be collected from the participant mills.
FFFFFor furor furor furor furor further detailsther detailsther detailsther detailsther details,,,,, mills ar mills ar mills ar mills ar mills are re re re re requested to visitequested to visitequested to visitequested to visitequested to visitour wour wour wour wour weeeeeb porb porb porb porb portal “tal “tal “tal “tal “http:// rmcysp.sitraonline.org”””””speciallspeciallspeciallspeciallspecially designed fy designed fy designed fy designed fy designed for this puror this puror this puror this puror this purposeposeposeposepose
THE SOUTH INDIA TEXTILE RESEARCHASSOCIATION (SITRA)
13/37 , Avinashi Road, Coimbatore Aerodrome Post,Coimbatore - 641014Phone: 0422 - 2574367-9, 4215333, 4215322 (Direct)Fax: 0422 - 2571896, 4215300E-mail: l&[email protected], [email protected] site: www.sitra.org.in
Jan. - Feb. 2013
SITRA News11
ANNUAL CONSULTANCY SERVICE (ACS) FORHUMIDIFICATION PLANTS AND COMPRESSORS
Mills are aware of the various services being offered by theEngineering division of SITRA. It has now initiated the above newservice for the benefit of spinning mills.
Humidification plants account for about 15% to 20% of the totalpower consumed in spinning mills, while air compressors accountfor about 6%. A modern spinning mill of 25,000 spindles consumesabout 1,50,000 units of electricity per month for Humidificationalone and about 45,000 units for air compressors.
Use of compressed air is increasing day-by-day in textile millsleading to increase in energy consumption. Studies reveal thatthe efficiency of the compressed air system is below 20%, with80% of the energy utilized for generating compressed air beingconverted into heat energy. So it is vital to reduce the losses incompressed air.
Towards this, SITRA has conducted many studies on the energyconsumption of air compressors. It is found that many mills arenot earnest about monitoring the energy consumption pattern,which leads to huge losses. A machinery manufacturer’s claim ofair consumption of individual machines and the measured actualconsumption varies widely. This apart, there is a wide variationamongst mills in the consumption pattern after one or two years,due to the maintenance practices followed and care taken to arrestair leakages. Improper maintenance and the inability to realizethe resultant energy loss leads mills increase the compressorcapacity.
Analysis of the date generated through SITRA Energy audits showthat there is huge potential for energy savings in the humidificationsystem and air compressors used in textile mills.
Keeping the above in mind, SITRA is introducing an exclusiveservice - “Annual Consultancy Service (ACS)” - for humidificationplants and compressed air system which will provide continuousand long term benefits to the mills.
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SITRA News
Scope of the service
Humidification system
· Air flow and distribution analysis - This study includes theactual quantity of air handled by the supply air plants andexhaust air plants
· Air washer efficiency analysis
· Heat load analysis - Based on the heat load analysis carriedout in all departments, the standard power required for thehumidification system namely supply, pumping and exhaustare derived and compared with the existing humidificationpower.
· Plant motor loading analysis - The loading pattern of the supplyair fan motors, exhaust air fan motors and pump motors areanalyzed.
· Temperature and RH% pattern analysis - Pattern oftemperature and RH% inside the departments of the mill isanalyzed.
Compressed air system
· Study on air leakage in main line and machines
· Air line pressure drop analysis in compressor
· Compressor loading / unloading pattern and saving potential
Details of the Annual Consultancy Service (ACS)
Contract details
· The contract period will be for twelve months.
· SITRA’s Technical expert will make 3 visits to mills duringthe contract period. Detailed study will be made on thefirst visit for 2 days and a report about the performanceand energy saving potentials of the plant will be submitted.
· Subsequent visits, each of one day duration, will be in the6th and 9th month of the contact period.
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SITRA News
· SITRA will provide support for the new additions /modifications on the humidification and compressor plants,if any required by the mills during the contract period.
· While the mill should take the responsibility to implementthe various suggestions given by our technical expert inthe report, SITRA will evaluate / assess the benefits / savingsdue to the implementation along with the mill technicians.
· The contract will be effected after the receipt of fullpayment
Charges
The Annual cost for the contract is as below.
§ Mills with spindleage up to 25,000 - ` 20,000
§ Mills with spindleage between 25001 and 50000 - ̀ 0.90/- per spindle.
§ Mills with spindleage above 50,000 - ̀ 0.80/- per spindle.
Actual Travelling and halting expenses of our technicalexpert will be charged extra during the mill visits.
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