Case Study Energy Saving in Textiles by Converting Shuttle loom to - - PowerPoint PPT Presentation

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.

3

4

Warp- Weft ( Tana-Bana)

Textile-saving 5

Basic Motions of Loom

Textile-saving 6

Basic Motions of Loom

Textile-saving 7

RAPIER LOOM

8 Textile-saving

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

9

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.

10

We have introduced Dwell mechanism. Rapier stops at end of shed.

Types of Rapiers

11

Rapier Double Flexible With Dwell Without Dwell Single & Rigid

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:

12

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

• f 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.

13

In-Situ upgradation scheme

14

In-Situ upgradation scheme

15

http://ministryoftextiles.gov.in/sites/default/files/news-mar/index.html#features/3

Developement

• Special Cam Mechanism with Dwell

16

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.

17

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.

18

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

19

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

20

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

IP Status

23

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.

24

Benefits

25

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.

Awards

26

Award ceremony at New Delhi

27

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.

28

• Dr. Kavita Gupta IAS,

Textile Commissioner declares In-Situ Scheme on 28.3.2016 at Bengaluru

29

Way forward

30

• 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

31

BEE guidance material Paper 4 - Textiles

32

BEE guidance material Paper 4 - Textiles

33

BEE guidance material Paper 4 - Textiles

34

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 bharatrapier@gmail.com www.srisaitextileconsultancy.webs.com

35