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Energy consumption of chosen spinning mill

In order to obtain the necessary information about energy consumption of a speci c spinning mill, one which is able to spin every
kind of staple ber (i.e. cotton, linen, polyester, viscose) in a wide count range using both ring and open-end systems to be
chosen.

By Textile School Last updated Mar 13, 2018

Table of Contents 

Accumulating the power consumption data

In order to obtain the necessary information about energy consumption of a speci c spinning mill, one which is able to
spin every kind of staple ber (i.e. cotton, linen, polyester, viscose) in a wide count range using both ring and open-end
systems were chosen. This spinning mill included not only machines used for manufacturing (blowing room, carding,
combing, drawing, roving, spinning, winding), but also included 5 air conditioning systems, 2 compressors and 2555
lamps for illumination. Besides this, the chosen spinning mill used only electrical energy.

Energy consumption on various machines

The unit power needed for corresponding machines in production line and power for the air conditioning system,
compressors and lamps can be seen in Table. Installed power is a power needed for each equipment if there is no energy
loss; the actual power was calculated taking into consideration energy loss or energy e ciency. The total installed and
actual power needed for each equipment given in the table was obtained by multiplying the number of machines with the
unit power required. The subtotal of each equipment group is also shown, i.e. subtotal of actual power necessary for
carding machines is 229.5 kW. In addition, the last column of the table shows the share of actual power required for each
equipment group in the total actual power consumption, i.e. carding machines form 9.44% of the total actual power
consumption. The amount of total actual power in the chosen spinning mill was determined as 2432.8 kW in which
machines, air conditioning, compressors, and illumination were included and the machines consumed energy which
formed 78% of the total energy consumption alone.

For unit machine For total

Number of Installed Actual Installed Actual Share of each in otal

Equipment Type machines power,kW power, kW power,kW power, kW actual power, %

Blow Room (Cot- 1 36.00 22.00 36.00 22.00 8.10

Linen Line)

Blow Room 1 64.00 42.00 64.00 42.00

(Automatic)

Blow Room 6 16.30 8.00 97,75 48.00

(Manuel1)

Blow Room 3 7.15 4.00 21,45 12.00

(Manuel2)

Blow Room 4 26.10 10.75 104,50 43.00

(Poly/vis)
 For unit machine For total

Number of Installed Actual Installed Actual Share of each in otal

Equipment Type machines power,kW power, kW power,kW power, kW actual power, %

Vertical Opener 5 9.40 6.00 47.00 30.00

SUB TOTAL – 158.95 92.75 370,70 197.00

Carding M. (Saco- 5 4.00 3.30 20.00 16.50 9.44

Lowell)

Carding M.(C10) 8 13.25 8.50 106.00 68.00

Carding M.(Rieter) 10 20.70 14.50 207.00 145.00

SUB TOTAL 37.95 26.30 333.00 229.50

Drawing Machines 14 10.00 7.50 140.00 105.00 4.30

Combing Machines 4 6.53 5.50 26.12 22.00 0.90

Lap Machine 1 13.00 11.00 13.00 11.00 0.45

Roving Machines 12 17.30 11.40 207.50 136.80 5.60

Ring Spinning 33 40.00 34.00 1320.00 700.00 28.80

Machines

Ring Traveler 10 0.497 0.30 4.97 3.00 0.10

Robots

Open-end Spinning 5 81.60 60.00 408.00 300.00 15.10

Machines 1
 For unit machine For total

Number of Installed Actual Installed Actual Share of each in otal

Equipment Type machines power,kW power, kW power,kW power, kW actual power, %

Open-end Spinning 1 100.00 67.50 100.00 67.50

Machines 2

Winding Machine 15.50 13.50 155.00 135.00 5.60

10

SUBTOTAL OF MACHINES 3078.29 1906.80 78.40

Compressor 1 1 58.00 40.00 58.00 40.00 2.63

Compressor 2 1 45.00 24.00 45.00 24.00

SUBTOTAL OF COMPRESSORS 103.00 64.00 103.00 64.00

Air Conditioning 1 110.00 55.00 110.00 55.00 16.00

System 1

Air Conditioning 1 147.10 91.00 147.10 91.00

System 2

Air Conditioning 1 147.10 116.00 147.10 116.00

System 3

Air Conditioning 1 126.00 73.00 126.00 73.00

System 4

Air Conditioning 1 81.50 55.00 81.50 55.00

System 5

SUBTOTAL OF AIR CONDITIONING 611.70 390.00 611.70 390.00

 For unit machine For total

Number of Installed Actual Installed Actual Share of each in otal

Equipment Type machines power,kW power, kW power,kW power, kW actual power, %

LAMPS 2555 0.04 – 102.00 72.00 2.98

TOTAL 3894.99 2432.80 100

Energy consumption for a chosen spinning mill in May

The chosen spinning mill operated in 3 shifts a day which consisted of 8 hours and also works 25 days a month.
Considering the monthly operating time and number of machines, the monthly (May) energy consumption of the chosen
spinning mill was calculated and all the data are shown in the following table. The actual total monthly energy
consumption of the spinning mill was 1459680 kWh/month in May as shown. 78.4% of this energy was consumed by the
machines, see Figure 1.a and 37% of the monthly energy consumed by the machines was due to the ring spinning
machines (Figure 1.b).
In order to determine the unit energy consumption of unit yarn mass which is known as speci c energy consumption, the
monthly energy consumption of the investigated mill was divided by monthly production quantity and the variation
obtained is demonstrated in Figure. The amount of speci c energy consumption changed between 3.23 and 3.76 kWh/kg
in the chosen mill among the selected months. These values were the average which changed depending on the yarn
properties.

Hourly energy Daily energy Monthly energy

Equipment Type consumption, kWh consumption, kWh consumption, kWh

Blow Room (Cot-Linen 22 528.0 13200

Line)

Blow Room (Automatic) 42 1008.0 25200

Blow Room (Manuel1) 48 1152.0 28800

Blow Room (Manuel2) 12 288.0 7200

Blow Room (Poly/vis) 43 1032.0 25800

Vertical Opener 30 720.0 18000

SUB TOTAL 197 4728.0 118200

 Hourly energy Daily energy Monthly energy
Equipment Type consumption, kWh consumption, kWh consumption, kWh

Carding M.(Sacolowell) 16.5 396.0 9900

Carding M.(C10) 68 1632.0 40800

Carding M.(Rieter) 145 3480.0 87000

SUB TOTAL 229.5 5508.0 137700

Drawing Machines 105 2520.0 63000

Combing + Lap Machines 33 792.0 19800

Roving Machines 136.8 3283.2 82080

Ring Spinning Machines + 703 16872.0 421800

Robots

Open-end Spinning 367.5 8820.0 220500

Machines

Winding Machines 135 3240.0 81000

MACHINE TOTAL 1906.8 45763.2 1144080

AIR CONDITIONING 390 9360.0 234000

SYTEMS

ILLUMINATION 72 1728.0 43200

COMPRESSORS 64 1536.0 38400

TOTAL 2432.8 58387.2 1459680

  energy consumption spinning spinning machine

Textile School - 393 Posts - 0 Comments

1 Comment

Shiva Says  6 months ago

The information shared by you is very useful but can you please tell me the number of spindles that you have taken under consideration?

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