book - 5 · core spun spandex yarn 5. organic cotton yarns & oe blended yarns (certifications...
TRANSCRIPT
301
First Prize Textiles
ARVIND LIMITED Gandhinagar (Gujarat)
Unit Profile
Arvind Limited is a textile manufacturer and the flagship company of the Lalbhai
Group. Its headquarters is in Naroda, Ahmedabad, and Gujarat, India. It has units
at Santej which manufactures cotton shirting, denim, knits and bottom weights
(Khakis) fabrics. It has also recently ventured into technical textiles when it started
Advanced Materials Division in 2011. It is India's largest denim manufacturer apart
from being world’s fourth-largest producer and exporter of denim.
In 1997, Arvind set up a state-of-the-art shirting, bottom weights and knits facility,
the largest of its kind in India, at Santej. With Arvind’s concern for environment a
most modern effluent treatment facility with zero effluent discharge capability was
also established.
The unit is certified with ISO 14001:2004, ISO 9001:2008 & in process of
implementing OHSAS 18001:2008.
Production Data
The Production of last two year is shown Below;
Year Production in MT
2012 – 2013 28774
2013 – 2014 35159
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Energy Consumption Data
Energy consumption data for last two Years is shown as below:
Years Electrical Energy in
Million kWh
Thermal Energy in Million
kcal
2012-13 210.30 398272
2013-14 211.80 484919
Specific Consumption Data A. Specific Electrical Energy Consumption Data for last two Year is shown as
below
B. Specific Thermal Energy Consumption Data for last two Year is shown as
below
Energy Conservation Measures implemented
Energy Saving Project No. 1: Improvement in Power Factor to 0.99
Power factor has been achieved by Installation Mixed power factor compensation
• Installation of APFC & Fixed capacitor at MCC panel & PCC panel
• Currently Power factor has been maintained by 0.99 from 0.94
• kVA Demand has reduced by maintaining PF to Unity
Energy Saving Project No. 2: Installation of Voltage Stabilizer in Lighting System – 30 KVA
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• Automatic voltage stabilizer has been installed in
lighting feeder capacity of 30 KVA
• Voltage level has reduced to 245 Volts to 210
volts
• Lumens level has been checked & maintained the
same
Annual Saving : Rs. 1, 39,650 per Annum Investment : Rs. 1, 00,000 per Annum Payback Period : 11 Months
Energy Saving Project No. 3: Replacement in 150 W Mercury lamp with 65 W LED lamps • There are total 350 Nos. of Mercury lamps installed
in plants.
• 62 Nos. of street light have been replaced with 65
Watts LEDs Lamps
• Others lamps are replacing with 65 Watts LED in
Phase-Wise
• Advantage of LED in street light
• Energy Saving - 85 watts Per lamps & More Lumens
& cleaner Light
Annual Saving : Rs. 2, 10,000 per Annum
Investment : Rs. 8, 99,000 per Annum Payback : 51 Months
Energy Saving Project No. 4: Replacement in 36 Watts x 2 nos. by 18 Watts x 2 nos. LED lamps
• There are total 3086 Nos. of 36 Watts X 2 Nos.
installed in Classical – 4 Area
• Replaced 36 Watts X 2 Nos. of FTL with 18 Watts X
2 Nos. LED lamps
• Advantage of LED in street light
• Energy Saving - 36 watts Per fittings
• More Lumens & cleaner Light
Annual Saving : Rs. 35, 60,530 per Annum Investment : Rs. 46, 30,000 per Annum Payback : 15 Months
Energy Saving Project No. 5: Installation of Energy efficient Centrifugal Air Compressor • Initially Compressed air was supplied from Common
Compressor House & Screw compressor were run to
cater additional demand.
• Sp. Power Consumption for Screw Compressor =
210 Watts/ CFM
• Install C700 & C1000 Centrifugal compressors of
165 watts /CFM
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Annual Saving : Rs. 8, 37, 00,000 per Annum Investment : Rs. 3, 50, 00,000 per Annum
Payback : 5 Months
Energy Saving Project No. 6: Installation of Pressure Reducing valve for Cleaning Air Application • Cleaning Air has been provided from Main
compressed air network.
• Pressure requirement for cleaning Air application is
not More than 2.5 barg.
• Pressure Reducing valve has been installed &
pressure 2.5 barg has been maintained at cleaning
Air header
• Time of operation has been also fixed for cleaning
Air. i.e. 9 hrs per day.
Annual Saving : Rs. 8, 12,000 per Annum Investment : Rs. 1, 50,000 per Annum Payback : 2 Months
Energy Saving Project No. 7: Replacement of Conventional H Plant with Fog
Type of H plant • Conventional Type of H Plant has been replaced
with Fog type of H Plant.
• Power Consumption Before Modification = 1200
kWh/ day
• Power Consumption After Modification = 600
kWh/day
Annual Saving : Rs. 16, 00,000 per Annum Investment : Rs. 23, 40,000 per Annum Payback : 18 Months
Energy Saving Project No. 8: Installation Loomspahare concentrated
Humidification plant in place of conventional • Installation Loomspahare concentrated
Humidification plant in place of conventional
• Power consumption for Conventional
Humidification = 72.0 kWh/loom/day
• Power Consumption for Loomspahare
Humidification = 54.0 kWh/loom/day
Annual Saving : Rs. 2, 28, 70,000 per Annum Investment : Rs. 1, 12, 00,000 per Annum Payback : 6 Months
305
Second Prize
Textiles
AARTI INTERNATIONAL LIMITED
Ludhiana (Punjab)
Unit Profile
Aarti International Ltd. represents a 100% cotton yarn manufacturing company,
with an installed capacity of 1,75,000 spindles including 43,400 spindles of compact
yarn. With state of art and technology plant located in Punjab, it has become a
global player in the spinning industry with manufacturing facilities of Slub and Core
Spun Lycra Yarn also.
The company was established in the year 1996 with 27000 spindles and slowly and
steadily expanded itself and has emerged as a global player in the spinning industry
with state of Art and Technology plant, with equipment from renowned machinery
suppliers from India, Switzerland and Germany.
INFRASTRUCTURE Aarti International is equipped with the state of Art machines and technology from
the world's top machinery manufacturers to serve the niche segments.
Preparatory Machines
1. Rieter, Trutzschler and LMW blow room lines for best cleaning results
Loptex Optosonic and SPFPU from Trutzschler for full control of contamination
in the opening process. It is the simplest and most effective system to
remove contamination in the spinning preparation line.
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2. Latest generation cards from Rieter and Trutzschler for higher productivities
and quality.
3. Latest generation of Zinser 68-i speed frames.
Ring Frames
1. Rieter Com4 and Suessen compact yarn Technology to produce best compact
yarns for high end weaving/hosiery applications.
2. Established a successful line of Ring Frames LR60 AX and RXi 240 from LMW
and KTTM
Winding
We have modular winding technology from Schlafhorst and Muratec to meet the
global demands of the textile industry.
Doubling Process
State of Art Technology for double yarns by Volkmann and parallel yarn winding by
Precision propeller winders for the best results.
Fancy Yarns
Amsler Slub yarn Technology and Pinters Core spun attachments add special values
to our product line.
Product Profile
Our top priority is providing efficient and reliable services to the customer. We are
aware that in order to continue as successful spinners we have to add genuine value
to the product. Our experienced staff is familiar with the needs of our clients and
well informed about the peculiarities of the yarn markets. We respect the needs of
every client and strive to satisfy them.
1. 100% Combed Cotton Grey Yarn
2. 100% Combed Cotton Compact Grey Yarn
3. Cotton Slub Yarn (Amsler)
4. Core Spun Spandex Yarn
5. Organic Cotton Yarns & OE Blended Yarns (Certifications from GOTS &
Organic Exchange)
6. Single and Double Yarn
All above products in the count range of Ne20 to Ne 40, for hosiery as well as
weaving applications from various cotton mixings. "90% of our yarn is exported to
high quality conscious customers in Hong Kong, China, South Korea, Taiwan,
Bangladesh & European markets. Product finally ends up in various internationally
accepted & well known brands like Tommy Hilfiger, Walmart, Gap, Marcs & Spencer
etc.
Accreditations
Aarti International Limited also has the following certificates and licenses:
WERNER INTERNATIONAL a management consultant specialized exclusively in the
fiber, textile and fashion industry globally since 1939 has stated that
"Globally, Aarti International Ltd is among the best managed and efficient cotton
spinning plant today, anywhere in the world."
• CERTIFICATE OF MERIT, Second Position Award from PEDA, Punjab (2009-10)
307
• USTERIZED quality certificate from USTER, Switzerland
• OEKO TEX Certificate from HOHENSTEIN, Germany
• CU Certification GOTS
• CU-Certification-OE
Best Engineering Practices
1. Daily power & losses monitoring for analyzing any deviation and timely
corrective action.
2. Energy conservation teams at various levels
a). Shop floor level workers
b). Officers & Managers
c). Head of Departments & Top Management
3. Regular suggestions are welcomed from all the workers and staff for
improvements and savings.
4. Cross functional teams of Production, Maintenance & Engineering are
regularly working for continuous improvement.
5. Regular use of Temperature / ultrasonic guns for monitoring machine health
and panel temperatures.
6. Compressed air consumption is monitored by thermal mass flow meters and
one team of maintenance; engineering is regularly working for detecting and
attending leakages.
7. Similarly regular monitoring of water pumped and consumed is monitored in
utility and workers colony.
8. Water and power saving training programs are organized for workmen.
9. For cost optimization regular thrust is given for local development of costly
OEM parts.
Health Safety and Environmental Policy
Aarti International Ltd., believe that Safety and Health of our employees and Safe
Working Environment are fundamental to our operations. We will ensure this and
continue our commitment to safety, health and environment by:
• Complying with relevant legal statutes.
• Using and maintaining Personal Protective Equipments, Systems and facilities
to provide a safe work environment.
• Conservation of resources and preventing pollution
• Creating awareness regarding safety, health and environment through
training sessions and internal communication.
• Continually improving safety, health and environment aspects through
objectives, targets and management programs.
• Continually improving environment performance of our processes & products
and ensure prevention of pollution at every stage.
• Strictly complying with the applicable environment legislation & standards.
• Ensuring effective use of resources in the areas of energy, fuels oils, water
etc.
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• Water treatment (de-scaling) to be carried out at regular intervals. Water
treatment is carried out at regular intervals
• To carry planned plantation and maintenance of gardens within the premise
of the company. The company boasts of being the first in its kind to have
planned plantations and gardens , giving workplace an amiable atmosphere
and contributing to the environment whilst ensuring a sustained ecological
balance
• Encouraging the usage of environment friendly technologies to aid elimination
of the hazardous materials.
• Promoting the cause of environmental protection and preservation amongst
employees and other parties by inculcating sensitivity to the environmental
concerns.
Process Flow Chart
MAJOR ENERGY CONSERVATION PROJECTS (YEAR 2013-14)
309
Certificate of Merit
Textiles
MARAL OVRSEAS LIMITED - SAROVAR PLANT
Khargone (Madhya Pradesh)
Unit Profile
Maral Overseas Ltd is one of India’s largest vertically integrated textile companies.
This export led company is a part of the $ 1114 million LNJ Bhilwara Group, whose
leadership in textile business is complemented by high technology sectors of
graphite electrodes and power generation.
Set up in 1991 at Maral Sarovar, it is a $ 139 million (834 crore rupees) composite
company. Maral has earned reputation of an extremely reliable supplier in the global
market having modern manufacturing technology, quality systems and quality
relationships.
The Energy Conservation is a top priority at MARAL OVERSEAS LTD (MOL). In view
of scarce energy resources in the competitive world market, green house, gas
emission etc., the commitment of the Company towards energy conservation is one
of the important aspects. All efforts are made to find out most energy efficient
equipments and replace them with the non efficient or less efficient working
equipments every time. Consistent efforts in R&D and technology in innovation are
also made to reduce the wastage level in order to become energy efficient Company.
310
Power & Specific Power Consumption
Single Yarn
Double Yarn
Knitted Fabric
Dyed Yarn
Power Consumption -Single Yarn
530.50
531.00
531.50
532.00
532.50
533.00
533.50
2012-13 2013-14
Specific Power Consumption - Single Yarn
2860
2870
2880
2890
2900
2910
2920
2012-13 2013-14
Power Consumption - Double Yarn
27.80
27.82
27.84
27.86
27.88
27.90
27.92
27.94
27.96
2012-13 2013-14
Specific Power Consumption - Double Yarn
1180
1190
1200
1210
1220
1230
1240
1250
2012-13 2013-14
Power Consumption - Knitted fabric
11.75
11.80
11.85
11.90
11.95
12.00
12.05
12.10
2012-13 2013-14
Specific Power Consumption - Knitted fabric
328
328
329
329
330
330
331
331
332
2012-13 2013-14
Power Consumption - Dyed Yarn
23.00
23.50
24.00
24.50
25.00
25.50
26.00
26.50
2012-13 2013-14
Specific Power Consumption - Dyed Yarn
1890
1900
1910
1920
1930
1940
1950
1960
2012-13 2013-14
311
Dyed Fabric
Thermal & Specific Thermal Energy Consumption
Single Yarn
Dyed Yarn
Dyed Fabric
Power Consumption - Dyed Fabric
49.00
50.00
51.00
52.00
53.00
54.00
55.00
56.00
57.00
58.00
59.00
2012-13 2013-14
Specific Power Consumption - Dyed Fabric
1230
1240
1250
1260
1270
1280
1290
2012-13 2013-14
Thermal Energy Consumption - Single Yarn
645
650
655
660
665
670
675
680
2012-13 2013-14
Specific Thermal Energy Consumption - Single Yarn
0.035
0.036
0.036
0.037
0.037
0.038
2012-13 2013-14
Thermal Energy Consumption - Dyed Yarn
5300
5400
5500
5600
5700
5800
5900
6000
6100
6200
2012-13 2013-14
Specific Thermal Energy Consumption - Dyed Yarn
0.00
1.00
2.00
3.00
4.00
5.00
6.00
2012-13 2013-14
Thermal Energy Consumption - Dyed Fabric
38500
39000
39500
40000
40500
41000
41500
42000
2012-13 2013-14
Specific Thermal Energy Consumption - Dyed Fabric
7.50
8.00
8.50
9.00
9.50
10.00
10.50
2012-13 2013-14
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Major Projects implemented for Energy Conservation at Maral
Overseas Ltd during the year 2013-14
ELECTRICAL
1. Replacement of Auto coner
In spinning unit there were six Auto coner of Schlafhorst make 238-146 model.
These machines were replaced with new generation Muratec energy efficient Auto
coner machines.
Measure Annual electrical saving : Rs.17.25 Lacs Investment : Rs. 1010 Lacs
2. Replacement of Comber
In spinning unit there were sixteen number of low production Rieter comber (Model
E 7/5) machines. These machines were replaced with eight numbers new generation
high production energy efficient Rieter Comber (Model E 80) machines.
Measure
Annual electrical saving : Rs. 12.96 Lacs Investment : Rs. 506 Lacs
3. Replacement of Unilap
In spinning unit two numbers of inefficient & low production Rieter Unilap (Model E
3/5) machines were replaced with new generation high production energy efficient
Rieter Omega lap (Model E35) machine.
Measure Annual electrical saving : Rs. 2.05 Lacs Investment : Rs. 159 Lacs
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4. Replacement of Finisher Draw frame
In spinning unit twelve numbers of inefficient, low production & quality Rieter Draw
frame machine (Model RSB 851) machines were replaced with nine numbers new
generation high productive & quality energy efficient Rieter Draw frame (Model D45)
machines.
Measure Annual electrical saving : Rs. 6.34 Lacs Investment : Rs. 260 Lacs
5. Replacement of Air Conditioner
Unit has replaced old ten number of inefficient air conditioner with star rated air
conditioners.
Measure
Annual electrical saving : Rs. 1.28 Lacs Investment : Rs. 4.3 Lacs
6. Replacement of LED Tube rod
In department Unit has replaced the conventional 2500 tube rod and electronic
choke with LED tube rod. Thus save the energy of 16 W with each replacement.
Measure Annual electrical saving : Rs. 21.43 Lacs
Investment : Rs. 28.75 Lacs
7. Replacement of Pumps
Total ten number of monoblock pumps replaced with energy efficient pumps to save
the energy.
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Measure Annual electrical saving : Rs. 3.5 Lacs Investment : Rs. 9.6 Lacs
8. Modification in compressed air line
In process area for cleaning of machine compressed air being used. This connection
taken from the machine compressed air line of high pressure. Unit has laid down
separate compressed air line for cleaning of machine at low pressure.
THERMAL
9. Reduction in process cycle time in yarn dyeing
Modification in yarn dyeing machine by installation of dynamic rinsing system to
reduce the process cycle time. The above modification carried out in 6 nos
machines.
Measure Annual electrical saving : Rs. 4.46 Lacs Annual thermal saving : Rs. 10.4 Lacs
Investment : Rs. 5.5 Lacs
10. Recovery of heat from flash steam
Recovery of heat carried out by using the flash steam of trap of Santax Progress
dryer machine of process house. The recovered heat used to increase the
temperature of boiler feed water.
Measure Annual thermal saving: Rs. 5.5 Lacs Investment : Rs. 1.2 Lacs
11. Recovery Hot water
Heat recovery by recycling m/c cooling water for process in dyeing machines.
315
Measure Annual thermal saving : Rs. 20.6 Lacs Investment : Rs. 20.5 Lacs
12. Reduction in process cycle time in Fabric dyeing machines by process
improvement
Project (PIP) undertaken with M/s Huntsman, USA to Optimize the process
(Scouring, pre-treatment aquacron and soaping process) and reduced process cycle
time in fabric dyeing.
Measure Annual electrical saving : Rs. 8.93 Lacs
Annual thermal saving : Rs. 38.88 Lacs Investment : NIL
13. Reduction in Re-dyeing in Fabric dyeing machines by process improvement
Project (PIP) undertaken with M/s Huntsman, USA and improved process robustness
and reduced re-dyeing in fabric dyeing.
Measure Annual thermal saving : Rs. 26.5 Lacs Investment : NIL