Retrofits & Accessories

for

Textile Process Houses

from

A.T.E. Enterprises Private Limited

Save
Cost

Retrofits
&
Accessories

Improve
Quality

Improve
Productivity

Critical challenges of Indian processing units

Quality

Productivity

Critical
challenges
faced by Indian
processing
units

High cost of capital

Water scarcity

Rising energy costs

Retrofits and utilities from A.T.E.

Improved productivity
Enormous saving in energy

Improved quality

A range of retrofits
and utilities that will
result in :

with a substantially low investment

and fastest ROI!

Save
Cost

Retrofits
&
Accessories

Improve
Quality

Improve
Productivity

Mahlo - Atmoset SMT 12

Save energy Save cost

Payback in just 8 months!!!

Mahlo Atmoset SMT-12 is an online

moisture control and monitoring
system, that controls the steam input
in drying cylinders by optimising the
drying process, thus saving heat
energy (30%-50% saving in steam
can be achieved) and results with
consistent quality output.

Steam consumed per kg. of fabric

processed on drying range (without
Atmoset SMT-12)

1.2 kg

Steam saved per kg. of fabric

processed (considering just 25%
steam saving with Atmoset SMT-12)

0.25 kg

So, steam saved after processing 21

MT (or 80,000 meters) of fabric per
day

0.25 21000
= 5250 kg

Considering 25 days working per

month, steam saved per month

1,31,250
kg/month

Cost of steam saved per year*

Rs.
25,20,000

Cost of Mahlo Atmoset SMT-12: Rs.16,25,000**

So, ROI = 7.74 months ~ 8 months
(*Cost of steam considered @ Rs.1.6/kg)

Reference: Alok (Vapi), Auro (Baddi), Welspun (Anjar), GHCL (Bhilad)

**Prices of equipment are indicative and are subject to change

Luwa - water to water heat recovery system

Payback in just 2 months!!!

Save energy Save cost

Input parameters

Output parameters

Waste water 20 m3/hr

Fresh water inflow: 20 m3/hr

Wastewater @ 80C
cooled to 41.15C

Fresh water @ 25C; heated up

to 63.57C

Thermal efficiency: 886.1kW

Fuel used: Firewood (calorific value of 3000 kcal/kg)

The shell and tube system

recovers heat energy from waste
water and uses it to heat fresh
water,
while
maintaining
constant
process
water
temperature by means of a PLC
attached to the system.

Cost of fuel: Rs. 3/kg

Total working hours per year: 6000
Fuel saving per year: 2177 MT
Cost of fuel saved: Rs. 65,31,900
Cost of Luwa water to water heat recovery system =
Rs. 8,50,000**
So, ROI = 1.56 months ~ 2 months*

Reference:
N.B: Performance depends on constancy of input parameters and maintenance

**Prices of equipment are indicative and are subject to change

Osthoff - online hairiness tester

Improved quality & cost savings

Payback in just 15 months!!!

A retrofit for the Osthoff singeing

machine for objective measurement of
the hairiness of the fabric for proper
control of the singeing process by
regulating gas intensity as per the
fabric hairiness, resulting in uniform
hairiness across the batch. Regulation
of gas intensity also results in saving of
gas.

Without
online
hairiness
tester

With online
hairiness
tester

Consumption of gas in kg/hour

15

11.5

Cost of gas in Rs./hour

945

724.5

Cost of gas in Rs./day

18,900

14,490

Cost of gas in Rs./month

4,72,500

3,62,250

Cost of gas in Rs./annum

56,70,000

43,47,000

Net savings (Rs./annum)

13,23,000

Cost of online hairiness system: Rs.1,625,000**

Cost of propane considered @ Rs. 63/kg
Working hours considered @ 20/day

Working days considered @ 25 days/month

Reference: Ruby (Khopoli), Oswal F.M. Hammerle (Kolhapur), GHCL (Bhilad)

**Prices of equipment are indicative and are subject to change

Monforts - infrared pre-dryer for CDR

Save energy Save cost

Payback in 50.4 months

A robust, third generation retrofit, made

of metal foam for the pre-dryer installed
on the CDR to reduce the moisture on
the fabric before it enters the hot flue, to
avoid migration of dyestuff. Varying gas
intensity with actual temperature
requirements (in the range of 600 to
800 C) results in saving in gas to the
extent of 25-30% as compared to
ceramic pre-dryers.

Parameter

Old

New

Consumption of gas in kg/hour

33 kg

20 kg

Cost of gas in Rs./hour

Rs. 2,079

Rs. 1,260

Cost of gas in Rs./day

Rs. 41,580

Rs. 25,200

Cost of gas in Rs./month

1,039,500

630,000

Cost of gas in Rs./annum

12,474,000

7,560,000

Net savings in Rs.

4,914,000

Cost of infrared pre-dryer for CDR: 295,000 or Rs. 20,650,000**

Cost of propane considered: Rs. 63/kg

Working hours considered: 20/day
Working days considered: 25/month

Return on investment: 50.4 months

Reference: Arvind (Ahmedabad), Auro (Baddi), Alok (Vapi)

**Prices of equipment are indicative and are subject to change

Save
Cost

Retrofits
&
Accessories

Improve
Quality

Improve
Productivity

10

Improve productivity Improve profit

Mahlo - textometer RMS

Description
A residual moisture
measurement
instrument for drying
ranges that controls
the degree of dryness
of the product by
means of dryer speed
based on the residual
moisture

Benefits
Improved productivity
Energy optimisation
Optimal residual
moisture for
subsequent
processing

References
Alok (Vapi), Oswal
Hammerle
(Kolhapur),
Vardhman (Bhopal),
Auro (Baddi), Birla
Century (Bharuch)

Mahlo textometer RMS can be used in stenter, pad steam and pad
dry, and CBR.
11

Improve productivity Improve profit

CEIA - bar metal detector

Description
This advanced textile
digital metal detector is
highly sensitive to all
magnetic and nonmagnetic metals. The
compact and robust
construction of this metal
detector with plug-andplay settings ensures a
high degree of protection
(IP 65 RC version)

Benefits
Highly reliable at a
wide range of speeds,
as high as 600
m/minute
Can detect ferrous and
non-ferrous metal as
small as 0.8 mm.
Prevents damage to
rubber rollers and
fabric
Higher machine uptime
Higher productivity
Higher safety
Better quality output

References
Alok (Vapi), Oswal
Hammerle (Kolhapur),
Vardhman (Bhopal),
Auro (Baddi), Birla
Century (Bharuch),
Jakharia (Boisar),
Mandhana (Boisar),
etc.

CEIA metal detectors can be used in shearing, calendar, shrinking

singeing machines, dye padder and CBR
12

Improve productivity Improve profit

CEIA - conveyor metal detector

Description
The THS 21 conveyor
satisfies the most
stringent requirements for
functionality, compact
construction, accuracy
and reliability of response
in dealing with accidental
metallic contamination of
products

Benefits
Very high sensitivity to
ferrous and all
magnetic metals
Detection sensitivity
compliant with the
textile industry
Standards
Digitally-adjustable belt
speed
Structure and metal
detector in AISI 316L
stainless steel
High flexibility: all parts
completely reversible
and modular

References
Welspun (Anjar),
SEL (Punjab), Trident
(Budhni)

CEIA metal detectors can be used in a multitude of textile related

applications
13

Improve productivity Improve profit

Mahlo - ecopac EMC-12

Description
Comprising of Ecomat
AML, textometer RMS
and Permaset VMT, The
ecopac EMC-12 monitors
and controls exhaust air
moisture, residual
moisture, and fabric heat
setting temperature
respectively, resulting in
improved productivity and
energy optimisation

Benefits
Improved productivity
Energy optimisation up
to 16%
Consistent quality

References
Alok (Vapi), Oswal
Hammerle (Kolhapur),
Vardhman (Bhopal),
Auro (Baddi), Birla
Century (Bharuch)

Mahlo ecopac EMC-12 can be used in stenters

14

Improve productivity Improve profit

Advance Cooling - compressed air dryer

Description
An innovative
technology which is CE
certified and available
in different capacities,
to provide moisture-free
compressed air to
pneumatic systems on
various machines.
Compressed air cools
the incoming air and
separates the moisture
via a timer-controlled
electronic drainage wall

Benefits
Higher machine uptime
Higher productivity
Long life of pneumatic
systems
Less maintenance

References
Manan Cotsyn (Boisar),
Valiant (Boisar), Sutlej
(Bhilad)

15

Improve productivity Improve profit

Advance Cooling - panel air conditioner

Description
CE-certified and
available in different
capacities, panel ACs
help protect costly
electronic equipment
from the heat generated
by drives in the
electrical panel as well
as dust and humidity

Benefits
Higher machine uptime
Higher productivity
Long life of electronics
Less maintenance

References
Alok (Vapi), Ruby
(Khopoli), BRFL
(Boisar), Kothari
Exports (Kolkata),
Khosla (Mumbai), etc.

16

Improve productivity Improve profit

Advance Cooling - water & oil chiller

Description
A unique system that is
CE-certified and
available in different
capacities to maintain
constant temperature of
the dye liquor and
chemicals in the trough.
This water chiller
circulates chilled water
around the walls of the
trough to maintain its
temperature at a
desired level

Benefits
Improved productivity
Evenly dyed fabric
Reduced re-dyeing
Minimum tonal and
shade variations in the
dyed fabric

References
Ruby (Khopoli), Auro
(Baddi), Raymond
UCO (Yavatmal)

17

Save
Cost

Retrofits
&
Accessories

Improve
Quality

Improve
Productivity

18

Corino - beating & brushing systems

Improved quality Improve profit

Description
A compact unit with the provision to
attach different brushing or beating
systems.
Used in singeing machines,
CBRs, and printing machines

Benefits

References

Improves productivity
Improves quality
Energy optimisation

Alok (Vapi), Oswal Hammerle (Kolhapur),

Vardhman (Bhopal), Auro (Baddi), Birla
Century (Bharuch)

19

A.T.E. - rotary drum filter

Improved quality Improve profit

Description
A compact unit with a brushing system
for removal of fluff from drums without
using water
Used in singeing / desizing
systems, CBRs, and CRP (Caustic
Recovery Plant)

Benefits

References

Improves productivity
Improves quality
Reduces maintenance

Alok (Vapi), Indocount (Kolhapur),

Himatsingka (Hasan), Birla Century
(Bharuch), GHCL (Bhilad), Aarvee Denim
(Ahmedabad), Welspun (Anjar)

20

A.T.E. - screen filter

Improved quality Improve profit

Description
A compact unit with screen type
brushing system for removal and
collection of fluff
Used in ETP inlet at preliminary
treatment stage and various
drainage outlet as well

Benefits

References

Reduces labour cost

Less maintenance
Hassle-free system

Chenab Textile (Kathua)

Mandhana (Boisar)

21

Rotovac - online dust & lint removal system

Improved quality Improve profit

Description
A compact unit with a spring-type
brushing system for automatic
removal and collection of fluff
Used in rotary and flat bed
printing machines

Benefits

References

Reduces labour cost

Less maintenance
Hassle-free system

Arvind (Ahmedabad), NSL Textiles

(Hyderabad), BRFL (Boisar)

22

Monforts - chambers for stenter, pad dry

Improved quality Improve profit

Description
Additional chamber with running
stenters, hot flues

Benefits

References

Improves productivity at low investment

India Dyeing (Erode), Alok (Vapi), BJ

Textiles (Naidupet)

23

Montimac - rail sewing machine

Improved quality Improve profit

Description
Rail sewing machine for head to
head stitching of fabric edges before
batching

Benefits

References

Reduces wastage of fabric

Improves fabric & stitch quality

BRFL (Boisar), Indocount (Kolhapur),

Shreeji Lifestyle (Dombivali)

24

Corino - guidance system for digital printing

machine

Improved quality Improve profit

Description
Compact unit that ensures uniform &
tensionless feeding of fabric to
printing machine

Benefits

References

Perfect feeding and winding of fabric

with uniform tension
Improves printing quality

Shreeji Lifestyle (Dombivali)

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Monforts - eco applicator

Improved quality Improve profit

Description
For controlled application of
chemicals (softener, hydrophobic,
hydrophilic, stain repellants, etc)

Benefits

References

Improves fabric quality

Reduces energy costs for drying /
increases speed

Not yet sold in India; numerous

installations abroad
References available on request

26

Dunline - endless rubber shrinking belts

Improved quality Improve profit

Description
For fabric shrinking on shrinking
ranges

Benefits

References

Uniform performance throughout the

life of the belt
No material defect
Improves fabric quality

Alok (Vapi), Raymond (Kolhapur), Arvind

(Ahmedabad), JCT (Pagoda), RMB
Denim (Surat), Century Denim (Indore),
etc.

27

Dunline - endless felts

Improved quality Improve profit

Description
For drying & giving feel to fabric
used on palmer drum of sanforizer,
relax dryer, printing dryer

Benefits

References

Designed to offer uniform performance

throughout the life of the felt; no
material defects
Improves fabric quality

Jindal Worldwide (Ahmedabad), Bhaskar

Denim (Bhopal)

28

Dunline - accessories

Improved quality Improve profit

Description
Topline belt safe compound
Topline safe wash

Topline belt lube

Topline paralel gauge

Topline surface contact thernmom

Benefits

References

Maintain and increase longevity of

the belt & felt

BRFL (Tarapur), Mandhana (Tarapur),

Oswal Denim (Lalru and Bhopal), Nahar
(Lalru), Bhaskar Industries (Bhopal),
Indocount (Kolhapur)

29

MAG - textile testing instruments

Improved quality Improve profit

Description
High quality textile testing instruments at
affordable cost

Benefits

References

E I Dupont India (Hyderabad), Alok

(Silvassa), Morajee (Nagpur), Alps
(Ghaziabad), Grasim (Bhiwani), Shree
Sidvinayak Texco (Ludhiana), Shree Balaji
(Ludhiana), Pratap (Ambala), Ahuja Cotspin
(Punjab), Garg Acrylics (Punjab), KPR
(Tamil Nadu), Keshar Multi Yarns (Kolkata),
Vishnu Cotton Mills (Kolkata)

Quality assurance
Support customization
Calibration & test certification
Provision of AMC and OMC

30

Valence - static discharge bars

Improved quality Improve profit

Description
Compact, sturdy and reliable static
discharge bars to eliminate electrostatic
charge on moving parts

Benefits

References

Improves safety
Helps to improve productivity
Helps to improve quality

Nahar (Lalru), Tex n Nets (Gurgaon), Jain

Textiles (Gurgaon), Surya Processors
(Ghaziabad), Alps (Ghaziabad), Kudu Knits
(Ludhiana)

31

A.T.E. - material handling system

Improved quality Improve profit

Description
Supply of all types of material handling
equipment to store and move textile
substrates from one machine to another

Benefits

References

Low effort transport system

Suitable for heavy loads
Trouble-free working

NSL (Guntur), Birla Century (Bharuch),

K G Denim (Mettupalayam), D Dcor
(Tarapur), Premier Fine Linens
(Perundurai), Trident (Budhni) and
Himatsingka Linens (Hasan), Welspun
(Anjar)

32

A.T.E. - lubricants and greases

Improved quality Improve profit

Description
High quality speciality lubricants which
can perform under extreme conditions
of speed, temperature & load. Different
purpose grease & oil, aerosol sprays for
wet and dry applications for trouble free
operation of machines for longer
duration

Benefits

References

Mandhana (Boisar), Alok (Vapi), BRFL

(Boisar), Valiant Glass (Boisar), Mudra
Lifestyle (Boisar), Ruby (Khopoli), Arvind
(Ahmedabad), Premier (Bengaluru),
Himatsingka Linens (Hasan), Vardhman
(Budhni), Nahar (Lalru), etc

Resists hydrocarbon washout/dilution

High load carrying capacity
Reduced sludge and deposit formation
Excellent oxidative and thermal stability
Low friction and less power
consumption

33

A.T.E. - textile automation control systems

Improved quality Improve profit

Description
Complete, customized retrofit and
automation solutions for the textile
industry

Benefits

References

Improves the performance of old

machines
Hassle free operation
Improves production of machines
Reduces operation time
Reduces operation cost

Welspun Syntex (Silvassa), Bhaskar

Denim (Bhopal), Balkrishna Synthetic
(Tarapur), Indorama Synthetic (Nagpur),
Arvind (Ahmedabad), JCT (Phagwara),
Premier (Coimbatore)

34

THANK YOU

35