Page 68 - May-June-2017

68 Part-2
Project Management
Articles In Last Chapter, regarding the Spinning and Weaving, causing failures/down times.
= Profit Management
we have mainly emphasized the arrangement of ceiling
height and lighting system. Finishing mills are bit more
Moreover, it is wiser to have separate building based on
complex, more energy hungry and more
allowing heats in different area to mix and trap.
environmentally challenged manufacturing setups. A
normal Finishing Unit (exhaust or continuous) mainly heat zones, rather than having one common building,
uses the following natural resources with non-natural Finishing Mills are more prone to expansions owing to
resource i.e. Chemicals. business dynamics. Investors pushing more production
• Power in same area normally challenge esthetic design of
• Steam initial planning. So a unit based, production expansion
• Water (Raw) is pleaded to keep WIP flooding levels into normal and
• Water (Soft) workable esthetics.
• Compressed Air
Steam/Water Savings
Consumption of power used on machines is not being Exhaust and Continuous are two main Finishing setups
discussed, it varies for every machine design. around. Continuous Finishing Setup can be further
Somehow, many power consumption saving ideas are sub-categorized in Woven and Denim Finishing Setups.
available in below discussion. Any finishing setup is comprised of series of chemical
treatment with either Wetting or Drying of fabric. Fabric
Building of Finishing Mills is being wet and then Dried atleast 2 ~ 5 times,
depending on the processes. All the operative cost is
utilized in Wetting/Drying of cost. Any Wetting/Washing
Treatment cost about 0.5 ~1.0 kg of Steam/kg of fabric
and 0.9 ~1 kg of steam for drying. (approximately 0.3
Ton to 0.6Ton for washing of 12 Oz fabric in 1000meter,
similarly about 0.75 Tons on drying of same).
Water Recycling
Water recycling by identifying the different streams of
water and re-using to main reserviour or other machines
is an approach that don’t need any more introduction.
Depending on processes, upto 20 ~ 25% of water can
be re-used without any treatment.
Turning Point
Contrary to lower height of buildings discussed for Saving one passage of Wetting or Drying will cut the
spinning and weaving sectors, finishing mills are expense of finishing by millions. There had been two
designed with high ceiling level in order to have more approaches in cutting the cost of finishing i.e. saving a
relaxed environment for workers. Underground fresh air wetting pass or saving a drying pass. In latest, practices
ducts can be opened in the finishing floors to freshen of European textile units, textile experts used to take
up the air and maintain oxygen levels. Exhaust fans advantage of semi-dry fabric (almost half drying) or
should be able to release heat/steam from top of roof. no-drying in certain processes i.e. no drying after
Powerless exhaust fans are exemplary for not only bleaching process and wet fabric feeding to
saving electricity but also efficient head throw out. mercerizing process or semi drying after washing
Exhaust fans fitted on the side walls are normally not process leading to stenter finishing etc.
effective. Heat trap zone are major reason for
employees ailment and low efficiency in summers. Heat Later on, with further, development in continuous
trap zones also effect electronics of the machines Squeezing techniques, there had been rolls like RHL
Roberto etc. which could squeeze more water out of the Somehow, we will here discuss, more futuristic efficiency is dissipated into heat by different means. has number of innovative ways to reduce quantity of
wash boxes required to achieve certain washing levels.
There is availability of 80C jacket water from 1MW gas
approach for the textile sectors which are producing
fabric before drying, almost cutting 40% drying cost. In
drying cost. engine is able to convert less than 43% of gas Engine, equal to 600 ~ 900kg. Further the hot flue from proposal. Washing efficiency is based on following main
Horizontal wash box vs vertical wash box, single
engine at flow of 15 ~ 20 M3/hour. There is capacity of
case of exhaust fabrics, vacuum drying is saving same
their own electricity with use of gas engines. Any gas
threading vs double threading are now common
steam availability from WHR boiler at exhaust of Gas
consumed into electrical energy. Same percentage of
WHR boiler is still available at 180C which is normally
factors.
released into air. Infact, this exhaust air is available for
Temperature of Water Shower on Fabric
quick and cost free drying of fabric, if injected into
Thermosole, Stenter, Hot flue chambers. Combining all
Use of pre-hot water in showers can save a lot
above sources, the steam requirement remains limited
(especially when pre-hot water from gas engine jacket
managed in central reservoir which is eventually more
to Dyeing/Printing Steamers only. is available). Temperature of all hot sprays can be
efficient than normal water spray and then consequent
Fabric washer heat (direct or in-direct water heating). Machines
based on hot spray washing will be cheaper as one
common heat exchanger can serve purpose,
consequently, individual heat exchangers are not
required saving a lot in machine manufacturing cost.
Number of squeezes on fabric to meet fresh waters
Intermittent squeezing can increase the washing
efficiency by 20%. Although, machine manufactures
add extra cost for intermittent squeezers, somehow,
there is saving of one wash box over every five wash
boxes. Another innovation is suction slots inside the
Liquid from fabric- wash box, which vigorously increase the exchange to
sucked and absorbed liquor inside the fabric and prove more efficient.
into the partially
Air and LIQUID Highly efficient wash boxes will reduce the use of water
squeezed from roll evacuated roll and hence will reduce usage of chemicals based on
Washing Efficiency recipe.
Water consumptions of the fabric depends on two main
factors, FIRST pollution of fabric when fed to washing End Note
machine i.e. mercerized fabric, Scoured Fabric or Dyed Savings in the finishing units are various. Certain
Fabric etc, SECOND Washing Efficiency of the washing innovations are there for supporting futuristic way of
Liquid expressed compartment. thinking. We to begin a new processing, new methods,
from fabric new techniques. Being competitive and being energy
Pollution of fabric can be reduced with vacuum slots efficient is never ending race. We need to take caution
wherever applicable in the process. Washing efficiency that we should not be left out in race.