by Engr. Kh. Mashiur Rahman | Aug 29, 2019 | Power & Energy
Electric Resistance Heaters
Electric resistance heaters are used for heating the glue applied over the print blankets, which holds the fabric in place. When the belt finishes its movement on the upper side and when it moves down, the glue gets dried, which has to be heated again to retain its properties before it is exposed to the fabric again. In place of electric heaters if infra-red heaters are used, the efficiency would be better and energy consumption will be reduced.
Reduced electricity consumption of about 4 kWh/hour per infra-red heater.
Better work environment.
This option of Electric Resistance Heaters is a technology modification option for heating of the print blankets on continuous printing machines. This is a measure applicable to all printing machines that use print blankets (endless), which are coated with adhesives for holding the cloth in place while printing.
Investment cost per infra-red heater is Circuit Maintenance Process . Thus, annual savings are calculated to be INR 86 400 (USD 1 920) for operation of one infra-red heater, replacing three electric resistance heaters. Payback period is less than a month.
Pentachlorophenol by di-chlorophenol
Di-chlorophenol is less toxic than pentachlorophenol and can serve the purpose of a print paste preservative (used also as size preservative) and hence could be used in place of penta-chlorophenol. The measure would result in toxicity reduction.
Next to the working time of the employees involved in the project and installation of the instructions, no extra costs are associated with this measure.
Experience demonstrates a fast pay-back, due to adequate chemical handling by employees, accident prevention and appropriate waste management.
Reduced toxicity. Reduced fire hazards. Microbial growth in effluent treatment plant is not disturbed due avoidance of toxicity.
Applicable in the print paste preparation section of the textile printing industries.
Investment is same (because, it is just replacement of input material). Annual savings in monetary terms is negligible, but there are great environmental benefits along with the operational ease of the effluent treatment plant.
by Engr. Kh. Mashiur Rahman | Aug 28, 2019 | Boiler
Condensation Pots
Leaking condensation pots are one of the main issues of energy loss in a steam circuit. Therefore have the condensations pots checked at least once a year. The status of the condensation pots is measured by experts with an ultrasound stethoscope. Malfunctioning of condensation pots results in excessively high condensate temperatures and pressures in the condensate circuit.
Steam traps must be installed at least after every 25 m in the main steam headers. The steam traps will remove the moisture from the steam lines and will avoid further condensation and thus prevent heat loss and will reduce fuel consumption.
Implementing this option results in reduced heat loss and hence reduced fuel consumption and reduced GHG emission.
Steam traps are required to be installed in the main headers for the removal of moisture and this option is applicable for all steam headers of longer lengths.
Investment is in the range of few thousand Indian rupees (INR), the savings depends on the diameter and length of the steam headers. The investment payback would be with in a year.
Reasons of wear of condensation pots are amongst others:
• Insufficient cleaning of the filter of the condensation pot (at least twice a year).
• Starting up the steam circuit too fast. Due to the hammer effect of water, the filth on the walls loosens and the condensation pots get choked.
Small diameter of the condensate pipes. Extension of the steam circuit with extra steam consumer can for example cause a capacity problem for the condensate pipes. Alternating pressures in the steam condensate pipe circuit negatively affects the performance of the condensation pots and causes extra wear. A general rule is that the condensate pipe should have at least the same diameter as the steam pipes and preferably a larger diameter.
This measure avoids the unnecessary energy consumption.
This option is applicable to all companies having a steam installation. When placing or replacing steam circuits it is useful to place a leakage detector after every condensation pot in the system.
Cost involved is the wage of a maintenance engineer. Replacing condensation pots can also increase costs. The measure of Condensation Pots reduces energy costs.
by Engr. Kh. Mashiur Rahman | Aug 28, 2019 | Power & Energy
Automatic Self Closing Valve
- Automatic Self Closing Valve – The moment a burner turns off, a natural draft can develop through the boiler and the chimney. A valve on the chimney that automatically closes when the burner is turned off, keeps the hot air within the boiler.
- In case this measure is implemented, the boiler better maintains its temperature and pressure. Boiler pressure is maintained during the night and therefore the boiler can quickly be started in the morning.
- This option is profitable in case the boiler is turned off or on stand-by overnight.
- The investment costs for an automatic valve range between INR 30 000 and INR 60 000. When the boiler is turned off at night or left on stand-by, this option can have a payback period of two years.
- There is a tremendous amount of information on the Internet about boiler efficiency. For instance, have a look at the boiler efficiency database. It may be Gas cylinder valve
Measuring the wastewater generation
This option supports you in getting an overview of the amount and quality
of the wastewater generated in your company.
Wastewater treatment is an important cost-driver in textile processing
and a major source of environmental pollution. Collecting and generating data
about wastewater generation are thus key steps to improve your efficiency in
textile processing. The reasoning behind it is quite simple: “if you don’t
measure it, you can’t manage it”. Using the generated data will help you
to draw a trend line of your performance over different time-periods
(benchmark), to identify improvement options and to set targets. With a
benchmarking process you can compare your performance internally as well as
externally, with industry averages or competitors.
In order to determine the generated wastewater streams you can use the following table. Please determine the processes where the largest amount of wastewater occurs. In the case of wastewater, it is not only the amount but also the quality, which count. Where possible, state the generated amount and specify key characteristics1 of your effluent to get information on its quality. If available, use data from the last fiscal year or the last quarter and state the chosen time-period in the table. Otherwise collect the necessary information. Also try to fill out the total wastewater generated, which should not simply add up rows above, but summarise wastewater generated by all processes.
For comparability reasons make sure to use
the same time-period (e.g. one fiscal year) for all processes. In case you do
not have the information and/or cannot collect it, try to fill out the table
based on estimates. In this case, mention in the comments line that the figures
are estimates.
To benchmark your performance and see your improvements,
use a “wastewater generated per unit” ratio. The “unit” should be the unit of
production that is most useful for you. Examples could be “m2 of
product” or “1 000 units of product” (e.g. my company generates X m3
of wastewater for every 1 000 m2 of fabrics produced). You can also
use a ratio based on wastewater treatment costs per unit.
The management option Measure your water use efficiency is also an interesting option to
help you improving your wastewater generation. While this option targets your
water output, Measure your water use
efficiency helps you to control and reduce the water you put in your
processes, contributing directly to reduce your wastewater generation.
by Engr. Kh. Mashiur Rahman | Aug 27, 2019 | Embroidery
Hand Stitching Machine
The activities of Hand Stitching Machine carried out in a production hall are often of a very diverse nature and the required lighting level (illumination) can vary accordingly. It is potentially inefficient to take the spots with the highest lighting requirement as the basis for the lighting of the entire hall. Instead, it is better to adjust the lighting to the specific needs of the different activities that are being carried out. The lighting of specific work places can contribute to an optimized situation, both from a comfort and an energy efficiency point of view. iii …
Auditing the stitching operations and stitched garments as per the required. In addition, light switches can be installed both separately in the halls as well as over individual workplaces to use the electricity more efficiently. For workplaces of Hand Stitching Machine close to the window, this measure is especially relevant where the worker can switch off the light over his/her workplace. Helping cutting department’s personnel to implement new solutions and systems. Energy savings depend on the required level of lighting at the work place and the level to which the overall lighting of the production hall can be reduced. Communicating with stitching operators about the requirements of a style / buyer. Recommending area in – charge about line and system planning techniques to obtain better quality.
Reporting to Quality Manager about any problem (or Forthcoming problem) in stitching department and suggesting the solutions for the same. Keeping supervisors and checkers aware of quality requirements of style / buyer. Moreover, a central lighting control system can be installed to be able to switch off the lighting system of an entire building at a given moment (e.g., at lunchtime or during the night). Helping stitching department’s personnel to implement new solutions and systems. The occupants of the building can individually switch the lights on again when they need it. An example can be given from a garment manufacturing industry in which there are number of workstations (stitching machines) in one big hall. The unit had earlier only hall lighting provisions (quite elaborate) but still the workers felt need for improvement in lighting at the work station. Realizing this each work station was provided with CFL light right at the workstation and reduced the hall lighting drastically. The industry also went in to utilize the solar lighting by modifying the work stations layout. These measures had resulted in reducing the electrical energy consumption and better lighting conditions of Hand Stitching Machine
QA QC
- Discussing the job work requirements of a style with the Quality Manager in advance.
- Communicating the style requirements and quality standard requirements with the vendors doing job work.
- Approving the samples produced by the various vendors in consultation with Quality Manager.
- Assisting Q.A (Stitching) in his work.
- Auditing the stitching operation and stitched garments and reporting the problems to Quality Manager.
- Discussing the style / buyer related quality requirements with Q.A and communicating the same to supervisors / checkers / operators.
- Other than the above mentioned individual responsibilities the Quality Assurance team also performs following functions:
- Assisting R & D team for its work on forthcoming styles.
- Making discussions and taking decisions on problems rose to suggest corrective / preventive action.
- Maintaining the discipline and work environment in the garments production area and assisting the compliance department.
- Fulfilling any other requirements that got raised due to introduction of new styles / buyers.
- Visiting the vendors’ premises to communicate the requirements to the individual job worker or in case of any quality related problem with the vendor.
- Auditing the product delivered by the vendors and analyzing it time to time for performance rating of vendors and deciding about the company’s policy about a particular vendor.
