Academic Research Graduation Project

USE OF DAYLIGHT IN GARMENT INDUSTRY FOR ILLUMINATION

Under the guidance of Prof. Pavan Godiawala

Arpit Gupta Jinal Shah

Department of Fashion Technology Semester VIII 21st May11 Batch : 2007 - 2011
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ABOUT PROJECT

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Studies
1. 2.

Garment Industry light illumination Survey :

18 units : 5 industries
Captures solar light rays Use of optics and mirrors to transfer Dispersion of light

Sunlight transferring equipment

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TOPICS COVERED

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 Introduction

Industrial light illumination

Literature Review Suns movement with respect to earth Secondary Research Ray Optics Reflective Surfaces
Experiments Conducted Sunlight lux tracking Artificial lights lux at varying distances Measuring the efficiency of lens

and consumption survey

Industries Covered Topics covered in

questionnaire Methods employed for lus value collection Findings

Solar Lighting System :

Model development References

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INTRODUCTION

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 Objectives Find out lighting levels of garment industry in terms of Lux Find out percentage of electricity bill is contributed by artificial light Maximize the use of daylight and minimize the use of artificial light by developing an apparatus Context Duration : 3 months Location : Gujarat

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LITERATURE SURVEY

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Terminology
Light
Release of light photons when their electron gets excited

Lumen
Quantity of light emitted by the light source

Lux
Lux is equal to one lumen per square meter.

Efficacy
The amount of light produced by a lamp measured in lumens,

as a ratio of the amount of power consumed to produce it, measured in watts.

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Terminology
Color Rendering Index
Scale : 0 100

Continued..

How a light source make color of an object appear to human eye

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Artificial Lights Details

Life 1000 Hours

Continued..

Type of Light

Lumen watt

per

X Relative Color Start Up Time efficiency Rendering (minute) based on HPS Index

Operating Cost

Incandescent Fluorescent

15-25 55-85

.75 12
7.5 24 10

19% 65%

Immediate Immediate

95 - 98 50 - 90

High Average

Compact Fluorescent Light 45-60 LED Mercury Vapor Metal Halide 70-120 50-60 80-100

46%
50 100 92% 46% 77%

Immediate
Immediate 27 25 34

65 - 88
70 - 90 50-60 70 -75

Low
Very Low Average Below Average

16 24
1.5 15 20 24

High Pressure Sodium (HPS) 75-130

100%

25-35

Low

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Suns movement with respect to Earth

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Solar Tracker
Dual axis solar tracker Working concept
LDR Electronic circuit Motor

Servo (preferred) Stepper

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Ray Optics
Basics of Optics Laws of Reflection Refraction Lenses
Converging Diverging

Concave lens
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Convex lens
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Reflective Surfaces

Material
Foylon Mylar C3 anti-detection film Flat white paint

Reflectance
95% light, 85% heat 92-97% light 92-97% light Absorbs infrared radiations 85% light

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EXPERIMENTS CONDUCTED

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Sunlight Lux Tracking

Context Place : Date : Time :
Vasna , Ahmedabad , Gujarat April 17, 2011 to April 23, 2011. 0700 - 1800 hrs.

Experiment 1

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Sunlight Lux Tracking

Minimum : 25000 lx. Average : 50,000 lx

Maximum : 65000 lx.

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Artificial Lights lux at varying distances

Experiment 2
Purpose : To know the variation in lux values with varying distance

and height Fluorescent Tube light (36W, 5600 lumens, length = 48)
Height from ground inches
78 84

Height from machine

46 52

90
96 All measurements in inches Height of workstation is 32"

58
64

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Artificial Lights lux at varying distance(continued)

Positions
Center % from distance of 0" % decrease from previous Corner % from distance of 0" % decrease from previous

0
100 na 100 na 100 na

Distance in Inches 12 24 36 48
91.71 91.71 91.93 91.93 72.64 72.64 77.52 84.53 79.61 86.60 47.89 65.92 59.87 77.23 63.05 79.19 32.15 67.13 42.58 71.13 49.79 78.97 20.63 64.18

60
29.81 70.00 34.77 69.83 14.60 70.78

Average %

78.92

81.31

Lengthwise

% from distance of 0" % decrease from previous

68.13

Graphical Representation

Percent lux reduction at center of the light 78.92%.

Percent lux reduction at corner of the light 81.31%. Percent lux reduction at corner of the light s side ( length ) 68.13%.
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Measuring the Efficiency of Lens used Experiment 3

Lens 1 : Convex 4 dioptre, 65mm diameter Lens 2 : Concave 4 dioptre, 65mm diameter
Reading without lens Final reading % drop in reading Square root Efficiency of each lens 303 267 0.881188 0.94 0.94

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Measuring the Efficiency of Lens used

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INDUSTRIAL LIGHT ILLUMINATION AND CONSUMPTION SURVEY

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Industries covered
Arna Artex Banswara Creative Gini & Jony

(18 units were covered)

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Topics covered in Questionnaire

No. of lights Height of the light fixtures Power consumption of all lighting equipments Total floor area Tasks being undertaken Area of work stations

No. of windows
Area of windows Lux Readings

(Data collected for each building floor)

Questionnaire

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Method employed for lux values collection

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FINDINGS

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Minimum Lux requirements

Offices

Required Lux 150 For trims storage

Stores
500 lux 700-800 lux 200-250 lux

For checking trims Storage of fabric

Cutting

For panel check and re-cuting

1000-1200 lux 700-800 lux 400-500 lux

For spreading and cutting For fusing and ticketing

Sewing

For checking,

900-1000 lux 500-600 lux

For pressing, Finishing, Loading, Normal Sewing, trimming

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Findings
Average Lux department wise
Department Wise LUX
Department Stores Cutting Sewing Finishing/Packaging
350 300 Average Lux

Study 1 : Survey

Average LUX 120.305 328.62 294.74 271.39

250
200 150 100 50 0 Average LUX

Garment Industry Departments

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 Percentage of work area : 51 %

SEWING FLOOR Average LUX at various points

400 350 300 250 200 150 100 50 0

318.54

327.77

335.7 270.24

Average LUX

229.9

Work Center Wise Avg Lux

Inspection Sewing At Sewing Table Needle besides Point needle point

Center Table

Ironing

Work Station in Sewing Floor

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Findings

Study 1 : Survey

Percentage of light Electricity Consumption of companies

Percentage of light Electricity Consumption of companies Factory units* % of light electricity Studied consumption Unit 1 23.01 Unit 2 11.45 Unit 3 10.48 Unit 4 10.43 Unit 5 19.63 Unit 6 9.19 Unit 7 12.63 Unit 8 13.91 Average 13.84

25

20 % of light electricity

15

10

% of light electricity

0 Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 Unit 8 Companies

* Represents buildings under one electricity bill

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Findings
Average area covered by each light = 17.24 sq. ft. Average window percent to floor area = 4.11%

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Findings
Analysis Excel Sheets Assumptions Operating hours per day are eight Limitations Variables

Continued

Work stations distance from the window and windows dimension.

Day light entering from the window varies at various times of the day. Difference in actual number of tube lights in working condition

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Findings

Study 1 : Survey Continued

Observations & Recommendations

Dirt on lights and casings : Scheduled Cleaning Reflectors & Casing misaligned : Re-align to proper

position
Focus of light on the work
Light over the sewing table gets blocked at the needle point. Lux reduced to 75%

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MODEL DEVELOPMENT

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Solar Lighting System

Concept Various Parts and its functions Drawings Technical 3D figures

Theoretical efficiency
Hypothetical study (example) Benefits & Limitations Future scope

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Working Principle

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Solar Lighting System

Drawings Technical 3D Working

Working

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Solar Lighting System

Maximum Theoretical Efficiency Surface
Lens 1 Lens 2 Reflector 1 Reflector 2 Reflector 3 Reflector 4 Reflector 5 Reflector 6 Reflector 7 Reflector 8 Efficiency

Theoretical Efficiency

Efficiency
0.94 0.94 0.85 0.85 0.85 0.95 0.95 0.95 0.95 0.95

Type of Reflective Material

Silica Glass Silica Glass Mirror Mirror Mirror Mirror Mirror Mirror Mirror Mirror

42%

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Solar Lighting System

Sl. No. 1 2 Base Servo motor Name Raw Material 20S.W.G. S.S. SHEET 120 X 660 Bought Cost Rs. 175 850

Costing

3
4 5 6 7 8 9 10 11

Coupling
Bearing no. 626 Vertical shaft Column Bearing no. 6002 Bearing housing Bearing no. 634 Motor shaft Bearing housing 2

S.S.
Bought S.S. ROD C20 X 360 S.S. Bought S.S. Bought Teflon Teflon

150
50 255 340 75 214 40 150 130

12
13 14 15 16 17 18 19 20 21 22 Total

Servo motor 2
Bearing no. 608 Second lens holder First lens holder Reflector holder 1 Reflector holder 2 Reflector holder 3 Nut, bolt & washer Electronic circuit Other equipments LDR

Bought
Bought Nylon Nylon Nylon Nylon Nylon S.S Self-made Bought Bought

850
70 100 100 20 20 20 40 2000 350 1800

7799

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Cost Benefit Analysis

Type of Cost Work Area Number of lights reqd for 600 lux Area covered by 1 setup Cost of 1 setup Total cost of 114 setup required 2000.00 260.93 17.50 5000.00 571428.57 Unit sq. m count sq. m Rs. Rs.

Tubelight + choke cost

Total setup cost + 3% failure cost Total cost

52186.05
716.69 14133.69

Rs.
Rs. Rs.

Return on Investment

3 years and 5 months

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Cost Benefit Analysis

Minimum lumens available from sun = 25,000lu/sq.m(@

1800hrs) Theoretical efficiency of model = 0.42 Lumens available at point of distribution = 10,500lu Area covered @ 1200 lux at point of work = 17.5m2 Average no. of clear sky days in Ahmedabad= 250 Total reduction in light cost = 63.5% Total reduction in Electricity bill = 7.42%

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Solar Lighting System

Benefits & Limitations

Benefits Dependence on artificial light is reduced. Value of Color Rendering Index is increased. Cost of electricity bill is reduced. Recurring cost of light is reduced The installation of the model doesnt affect the existing building structure Limitations The light cannot spread evenly Heating up of transfer tubes is a big constraint. Works during the day time only Prototype
Depends on how big is the capturing glass & reflecting mirror

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Conclusion
Efficiency can be increased

Future Scope

The equipment can be used at other manufacturing facilities

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References
Institutions National Productivity Council, Gandhinagar Gujarat Energy Development Agency, Ahmedabad Indian Institute of Technology, Gandhinagar National Institute of Design, Ahmedabad British Library Books Mottier, Patrick. LEDs for Lighting Applications. Google Books. Web. 28 Feb. 2011. Schubert, E. Fred. Light-emitting Diodes. 2n ed. Cambridge. Google Books. Web. 20 Feb. 2011. Online Resources
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Thank You

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