Introduction It can be automated through automatic dampers Head* d, d

which will close if machine is going to off-state. This RPM

The specific consumption of electricity in Textile will increase the pressure due to automatic damper
90,000 40 15 1050 15.0 0
Spinning Mills is not optimum as observed during closure and will be detected through feedback signal
60,000 55 14.5 875 9.0 38
energy audits conducted under Cleaner Technology by the PLC or VFD. Then VFD will regulate it with fan
30,000 70 14.2 800 5.68 60
Project for Textile Spinning Sector (CTPTS). Electrical motor. So, a precise control can be achieved. This
*This table is for 1400 mm diameter fan at 40 mm
Energy is common power source for driving machinery, technique can save15-20% energy. The figure below
pressure head at the same speed of 1050 rpm
lighting, control system, compressed air system and is the model used for automation of blow and carding
office equipments. The purpose of this leaflet is to filters.
The above table shows the comparison of flow control
emphasize on the effective use of electricity through through dampers and VFD and the resultant power
automation. saved in case flow from 90,000 to 30,000 m3/hr. It is
clear from the table that there is no considerable
In textile spinning mills, system improvement through decrease in power in case of damper control as
automation (without affecting the machines production compared to the drastic change through speed
rate) has a very high electrical energy saving potential. control.
Following are some automation recommendations to
achieve energy efficiency in spinning mills.
Suction Pressure Control in Auto cone Machines
Blow Room Off-load Reduction
Auto cone suction motor removes fluff and maintains
During opened cotton transportation from blow room, the suction pressure depending upon the specific count
the material transport motor goes to off-state value but due to the accumulation of fluff in the fluff
whenever the pre-determined limit comes but all the suction box, the suction pressure varies, the machine
other motors such as beaters, rollers, condenser fans, pressure readings change depending upon the type of
dust fans remain in on-state resulting in the energy count. It is observed that the pressure may exceed or
wastage. The idle running of motors may vary from 7- decrease depending upon the value of count, yarn
9 hours. composition and cone status whether it is starting or
Pneumafil Fans on Ring Frames
ending.
By installing stop motion circuit, all these off-load
running motors can be stopped and then restarted at In Ring spinning, old pneumafil fans are used without The proposed action is to install VFD for suction
pre-determined levels with the increase in demand. variable frequency drive i.e. VFD. So, it is better to motor energy control using pressure signal feedback
replace them with energy efficient ones and use VFD that optimizes motor to the pressure requirement.
Energy Saving Calculations: (For single line) to effectively control the fluff and fan power. Normally the pressure requirement in auto cone
section is 85 mbar.
Total off-load Power, kW 16.3 The newer energy efficient fans along with VFD
(installed) consume about 20-35% less energy. Using variable frequency drives about 20% energy
Power consumption @70% load, 11.41 can be saved at the auto cone section.
kW
Motors off-load hours/day 9 Control of Axial Fan Flow
Humidification Plant Control
Units saved, kWh /day 102.7
Annual units saved, kWh /year* 35,941.5 Normally, fan flow is controlled in spinning mills
Water spray plant consisting of fans and pumps is the
Annual Rs. Saved @ Rs 5.0 /kWh 179,707 through dampers according to the demand level but
basic humidification plant used during yarn
* annual working days = 350; this is not energy efficient technique.
manufacture and conditioning. Normally all the
pumps and fans keep running at scheduled settings in
Dust Collector Filters (Blow Room & Carding) The energy efficient method is to effectively control
all weather conditions because no humidity control
through speed because speed is related with power
system is installed.
In carding and blow room sections, the waste consumption in cubic. At 50% speed reduction, the
filtration system is not automated as per count power required is only 12.5% of the rated value,
When humidity in fresh air increases like in monsoon
variations, machines on-off and composition of cotton excluding system and drive losses.
and winter season, the humidification system fans
mixture. Suction filter fans run at 70-80% of their keep running and a part of fresh air is re-circulated
rating all the time which is the cause of un-necessary Air Damper Speed Control
during good weather condition which causes extra
energy utilization. delive Control
energy consumption.
red in Pressu kW Fan kW %
m3/hr re Spee used save
In humidification plant, a substantial amount of For pressure optimization with yarn count, we have to
energy saving can be achieved through feedback analyze the yarn tenacity and hairiness factors. The
control automation to provide the temperature and pressure requirements greater than 28 mbar does not
percentage relative humidity (%RH) feedback signals further improve the yarn quality. It is possible to spin
to the VFD and then control the speed of supply air the yarn at even 18 mbar to meet the customer
fan. demands.

The following table next shows department wise

ranges for temperature (oC) and relative humidity
(%RH) requirements for spinning mills.

Section Relative Temperatur

Humidity, e (oC) Generally, the high yarn quality with low spindle
% RH speed is preferable by yarn manufacturers
Mixing 60-65 27-35 irrespective of the vacuum requirements of a specific
Prepara 50-55 27-35 yarn count. The point is that the vacuum requirement
tory is different for each yarn count. It varies from 18 to
Ring 50-60 27-35 34 mbar for two yarn counts of Ne 30 and Ne 70. References:
Auto 60-65 27-32 • www.rieter.com
The value of specific energy consumption rises as the • CTPTS Lahore case studies
cone • SITRA India
Carding 50-54 38 yarn count becomes finer as the vacuum
• Fuji Electric FA Components & Systems Co.,
requirements is more for finer count as compared to Ltd.
The proposed actions for humidification plant control coarser counts. • Investors manual for energy efficiency
can give the industry an energy saving of about 25% • SPINNOVATION No. 23- The magazine for spinning
From energy point of view, the overall energy saving mills
of its energy use. -www.suessen.com
for yarn of a Ne 30 is approx. 5% and for a Ne 70 it is
Effect of Vacuum on Specific Energy Consumption (SEC) up to 15%.
January, 2009
The figure below shows the effect of vacuum on
Specific energy consumption in ring frames is an
energy consumption of ring machine.
important factor to calculate the energy used by each
type of machines, running in the same environmental
conditions, for specific count of yarn production.

The figure below shows the yarn produced in g/Sph

for each spindle depending upon the yarn count in
comparison with SEC in kWh/kg.

Automation
For
Textile Spinning Industry
Cleaner Technology Project
For Textile Spinning Sector (CTPTS)