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INDIAN TEXTILE INDUSTRY

School of Energy & Environmental


Studies
Devi Ahilya Vishwa Vidhyalaya
Indore
Submitted To:
Lect.Mr. Rajesh Singadhiya
SEES
DAVV Indore

Submitted By:
Tushar Garg
M.Tech 2014-16
Energy Management

INDIAN TEXTILE INDUSTRY


BEE has identified 90 Textile units as designated consumers from textile industry.
In the base line year 2007-10,these DCs had a total energy consumption of 1.2mMTOE
per year Which is 0.73 % share of the total 478 DCs total annual energy consumption
of 164.97mMTOE.
The threshold limit is 3000 MTOE for Designated Consumer from textile Industry .
S. No.

Textile Sector

No's of DCs

Sub Sector

With CPP

Without CPP

Total

Spinning

33

36

Processing

15

20

Composite

24

28

Fiber

Total

78

*CPP Captive Power Plant

6
12

90

The 90 DCs are owned by 78 companies, comprising one cooperative and 77 private
sector companies.
No's
States
No of DCs
These DC are spread over 10 states.

of Textile
1

Andhra
Pradesh

According to CII Indian textile industry


contributes about

Gujarat

11

Haryana

11% To Industrial Production

Himachal
Pradesh

14% To Manufacturing Sector

Karnataka

Maharashtra 14

12% To Countrys total export earnings

Madhya
Pradesh

Direct Employment to 35 million people

Punjab

11

54.85 million people in its allied activities

Rajasthan

31

10

Tamilnadu

Total

90

4% to GDP

WORLD SCENARIO IN CONTEXT OF INDIA


Nos Spinning Capacity
2011

World
Millions

India
Millions

% Share
In world

India
Rank

Spindles-Cotton

205

48

22

Spindles-Wool

15

Rotors

0.8

Weaving (in Millions Tons)


1

Shuttle Looms

4.5

2.3

51

Shuttle less Looms

1.6

.15

Handlooms

3.6

2.4

67

Total Looms

9.7

4.85

50

Source: ITMF reports and GOI publications CITI

Broad Structure of Indian Textile Industry

ENERGY COST
Energy Cost in the textile Industry accounts for 5 to 17 % of the total production cost.
Acc. to Asian Research programme in energy ,environment & climate survey, the energy
Consumption of the textile industry is
3 to 3.5 kWh/kg of yarn in a modernized spinning mill.
0.09 to 0.2 kWh/kg of fabric in knitting units
0.04 to 0.15 kWh/kg of fabric in dyeing.
In fabric dyeing units ,consumption of steam may vary from 4 kg to 9 kg of steam per kg of
fabric.

SPECIFIC ENERGY CONSUMPTION


Specific Energy Consumption varies from 0.199 to 5.2 toe/t across
the sector.
The Identified DCs from Textile industry have been mandated to
reduce their total energy consumption by 0.066 mMTOE, which is
1 % of the total national energy saving target of 6.68 mMTOE under
the first PAT (Perform, Action & Trade Mechanism) Cycle 2012-15.

TEXTILE INDUSTRY PROCESSES


1.BLOWROOM
Blow room is the starting of the spinning operation
where the fibre is opened, cleaned, mixed , micro
dust removed and evened thus passed to carding
machine without increasing fiber rupture,broken
seed particles and without removing more good
fibers. The basic functions of blow room are
opening, cleaning, dust removal, blending and
evenly feeding the material on the card .
2.CARDING
Carding is a mechanical process that disentangles, cleans and intermixes fibres to
produce a continuous web or sliver suitable for subsequent processing. This is achieved
by passing the fibers between differentially moving surfaces covered with card clothing

3.SPINNING
It is the Process of twisting the fiber. The amount of twist given the yarns
determines various characteristics. Light twisting yields soft-surfaced fabrics,
whereas hard-twisted yarns produce hard-surfaced fabrics, which provide
resistance to abrasion and are less inclined to retain dirt and wrinkles. Hard
twisted yarns are used in producing hosiery and crepes.

4.WEAVING
Two sets of yarns, called the warp and the woof (more commonly filling, or
weft) are used in weaving, which is carried out on a mechanism known as a loom. Warp
yarns run along the length of the loom; filling yarns run across it. Different patterns
and textures are achieved by varying the number of warp yarns and by altering the
sequence in which they are raised or lowered.

5.KNITTING
Knitting refers to interloping of one yarn system into vertical columns and horizontal
rows of loops called wales and courses, respectively. There are two main types of
knitting: weft knitting and warp knitting.
Knitting is a method by which yarn is manipulated to create
a textile or fabric.
Knitting creates multiple loops of yarn, called stitches, in a line or tube.
Knitting has multiple active stitches on the needle at one time. Knitted
fabric consists of a number of consecutive rows of interlocking loops. As each
row progresses, a newly created loop is pulled through one or more loops
from the prior row, placed on the gaining needle, and the loops from the
prior row are then pulled off the other needle.
Knitting may be done by hand or by using a machine.

6. DYEING AND PRINTING


The fabrics can be dyed after weaving or knitting is completed (piecedyed).The loose fibers can be dyed in a vat (stock-dyed) or the yarn or
filament can be dyed before weaving (yarn-dyed).
Overview of Installed Capacity in A Textile Mill
Description

Installed, kW

Total load, %

Blowroom

58.78

2.39

Carding

327.6

13.32

Drawframe

61

2.48

Ring frame
(Spining)

1,158.88

47.12

Humidification
plant

284.3

11.56

Compressor

93

3.78

Energy Consumption Share of Each Specialized Technical Field in the Textile Industry
Specialized Technical
Field
Fiber production
Spinning
Twisting
Textured- yarn
production
Weaving
Knitting
Dyeing
Clothing manufactur ing
Others
Total
Unit million

Fuel

Electricity Total

Share%

21,498

54,049

21.0

44,262

47,480

18.4

1,660

1,879

0.7

1,543

1,663

0.6

4,467
4,059
37,661

24,848
11,709
28,412

29,315
15,858
66,073

11.4
6.1
25.0

8,240

15,420

23,660

9.2

5,959
96,500

12,000
161,442

17,959
257,942

7.0
100.0

32,551
3,224
219

120

Department Wise % Steam Consumption in a Textile Mill


Processing

65%

Sizing & Size Mixing

15%

Humidification in weaving and


spinning

10%

Unaccountable due to Engineering


,line losses, leaks

10%

Total

100%

Sr.
No

Steam Consumption in Unit


Operations and Stages of Wet
Processing
Steam
Dyeing process
consumption in
Kg / Kg of fabric

Dyeing in jigger or
winches

3.5

Dyeing in H.T.H.P.
dyeing machine

Pad dry steam drying

Pad - dry cure/thermo


sole dyeing

There are six production processes involved in the manufacture of knitted garments:
Knitting: Knitting is the first step, in which, the fabric is made from yarn. The output is in
the form of a hose.
Scouring: The knitted fabrics are scoured in a bleaching or dyeing unit by boiling with
caustic soda in open tanks. The fabric is then washed in freshwater.
Bleaching: In the next slide Figure gives the process chart of the bleaching operation.
Bleaching is done manually, or mechanically in a winch.
Dyeing: In the next slide Figure gives the details of the dyeing process. Calendaring: After
bleaching/dyeing, the fabric is passed through steam heated rollers in the steam calendaring
machines.
Finishing: After calendaring, the fabric is ready to be made into garments in the finishing
units. These units use electrically operated stitching machines and electric irons. Some of the
processes like embroidery require sophisticated computer controlled machines.

The Salient Features of the Resource Flow Analysis

1.The industry in Tirupur consumes 90,120 cubic meters of water every


day (i.e. 90.12 million liters/day) that equals the average water supply to
an Indian town with a population of over 2 million people.
2.The area is dry. Most of the groundwater is polluted and unusable.
3.More than half this quantity of water is brought to the town by trucks
from distances of over 50 km at a total estimated cost of US$ 6 million
per year.
4.The wastewater containing dyes and chemicals is discharged untreated
into a dry river.
5.The town consumes 62,530,000 kWh (i.e. 62.5 million kWh) of
electrical energy per year, including the power generated by diesel
generators. (Most units have diesel generators to overcome the erratic
power supply.) No estimates are available of the diesel consumed.

6.Nearly half a million tones (437,760 tones) of firewood, chopped from the
nearby forests, are needed annually for the steam calendaring, bleaching and
dyeing operations
7.Almost fifty thousand tones (49,862 tones) of chemicals other than dyes are
consumed annually. The majority of the reacted chemicals are discharged
through the untreated wastewater.
8.Around fifteen hundred tones (1,470 tones) of dyes are used annually, of which
an estimated 292 tones find their way into the wastewater (i.e. almost 1 tone of
dyes per day).
9.An estimated 3,171 tones of paper waste, 9,430 tones of textiles waste (rags
and threads) and 59.25 tones of plastic wastes are contributed annually by the
industry to the municipal solid waste (MSW). In addition to these combustible
wastes, over 40,000 tones of ash is also disposed of. In total, the industry
contributes 56,492 tones annually to the MSW.
10.In addition, an estimated 91,250 tones of domestic solid waste are generated
annually. Both the industrial and municipal wastes lie littered, untreated all over
the town.
11.An estimated 2,430 tones of plastics and 25,532 tones of waste rags, and 20
tones of metals are collected annually, and taken out of the town for reuse or
recycling. No information is available on the fate of these resources

ENERGY CONSERVATION OPPORTUNITIES


Use of variable frequency drives for fans of humidification plants.
Use of smaller wrap diameter spindles
Installation of radio frequency driers
Use of foam technique for printing and finishing.

Use of renewable energy, specifically solar thermal applications for


generating low grade heating.
Energy efficient automatic waste evacuation system with polymer pipeline.

Reducing warve dia of ring spindle.


Adiabatic nebulization and similar humidification system.

REFERENCES
1.http://www.textileschool.com/articles/109/blow-roofunctions#sthash.MFfx0rZS.dpuf
2.Info Source: PAT Book 2012 ,CII Super Directory 2012 Ministry of Textiles,CITI
3.Survey of energy conservation in India 2014
4. International Journal of Power System Operation and Energy Management ISSN
(PRINT): 2231 4407, Volume-2, Issue-1,2
5. J. Inst. Eng. India Ser. B (MarchMay 2013) 94(1):5360

DOI 10.1007/s40031-013-0040-5
6. Case Study Of The Textile Industry In Tirupur
7. M.Gohul, A.Mohamed Syed Ali, T.G.Raju, M.R.Saravanan, Dr.A.Pasupathy /
International Journal of Engineering Research and Applications (IJERA) ISSN: 22489622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.1421-1427

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