Energy Conservation /management in

Textiles
BY

DEEPAK KUMAR ABHISHEK TIWARY

FINAL B.Text TC T.Y. B.Text MMTT

DKTE’S TEXTILE & ENGINEERING INSTITUTE,

ICHALKARANJI
INTRODUCTION
The textile industry retains a record of the lowest efficiency
in energy utilization and is one of the major energy
consuming industry.

34% of energy is consumed in spinning

23% of energy is consumed in weaving

38% of energy is consumed in chemical

processing

another 5% of energy is consumed for miscellaneous

purposes
WHAT IS ENERGY

Energy is defined as "the ability

to do work."
SOURCES OF ENRGY

Renewable

 Nonrenewable
 BLEACHING

All the bleaching operations and washing are

steam consuming. The consumption of steam
(energy), for the conventional bleaching
process is about 6 kg/kg of cloth bleached.
 BLEACHING

COLD PAD-BATCH METHOD

This PROCESS requires peroxodisulphates.

The other compounds which accelerate the peroxide reaction

are urea, glucose, sodium citrate, methyl carbonate and tetracetyl
ethylene diamine. With this method there win be considerable
reduction in cost of production due to savings in energy,
water and labour.
BLEACHING

FOAM BLEACHING COMPOSITION

By using foam, the chemicals with a very low amount

of water (30­40% owf) can be applied
over a large surface area of the substrate, thereby,
reducing the energy input of the process
BLEACHING
BTRA RAPID PROCESS
THE GRAY FABRIC IS PADDED WITH 50-52°Tw
NaOH & STEAMED FOR 3-5 MINUTE THEN WASHED
.
ON MERCERISING RANGE.
AGAIN FABRIC IS PADDED WITH NAOCL (3-5 GPL)
& FABRIC IS KEPT FOR 5 MINUTE THEN AGAIN
FABRIC IS PADDED WITH 1.5 TO 2% HYDROGEN
PEROXIDE WITH SODIUM SILICATE AND SODA
ASH AND NON-IONIC DETERGENT. THEN FABRIC
IS WASHED AND DRIED
THERE IS CONSIDERABLE SAVING IN TERMS OF
TIME, ENERGY AND LABOUR.
BLEACHING
NOVEL METHOD
COMBINED DESIZING, SCOURING AND BLEACHING OF
POLYESTER/COTTON BLEND FABRICS CAN BE DONE EVEN IN THE
PRESENCE OF METAL IONS COULD SUCCESSFULLY SYSTEM USING
A MLR OF 1: 25.

BATH CONSISTING OF
HYDROGEN PEROXIDE (35% W/V),
MAGNESIUM SULPHATE HEXAHYDRATE (1.6 GPL),
SODIUM HYDROXIDE (4 GPL),
ANIONIC/ NON-IONIC WETTING AGENT (0.5 GPL)
EDTA (2 GPL)
GLUCONIC ACID (2 GPL)
95°C FOR 60 MINUTES WAS USED.
THE TREATMENT IS FOLLOWED BY A THROUGH WASH AT 95°C.
DYEING

IT IS OBSERVED THAT A LARGE PROPORTION OF

ENERGY CONSUMED DURING DYEING PROCESSES
IS IN HEATING & EVAPORATING OF WATER. SO
LESSER WATER IN TEXTILE WET PROCESSING CAN
INSREASE SAVING.

THREE METHODS OF SAVING ENERGY

EXPRESSION
TRANSFER
 LIMITED OR TOPICAL APPLICATION
DYEING

SUCTION ROLLER EXTRACTOR

THE WET FABRIC IS PASSED OVER A VACUUM SLOT

AND THE EXCESS WATER IS SUCKED.

MOISTURE LEVEL CAN BE REDUCED TO 45-50 %.

DYEING

SWIMMING ROLLERS

IT IS POSSIBLE TO TOTALLY ELIMINATE USUAL

DEFLECTION OF THE ROLLERS WHEN
PRESSED AGAINST EACH OTHER WITH A
PRESSURE SAY, 2-10 TONES.
DYEING

FIBER FILLED ROLLERS

THERE ARE TWO ROLLS, THE BOTTOM ONE BEING

MADE OF STEEL, WHILE THE TOP ONE IS COMPOSED
OF POROUS MATERIAL.

MOISTURE CONTENT CAN BE REDUCED TO 30-45 %.

 DYEING

TRANSFER METHODS

LOOP TRANSFER PROCESS

TRANSFER PADDING
DYEING

KISS ROLL METHOD

THE QUANTITY OF LIQUOR APPLIED IS REGULATED BY

THE RELATIVE SPEEDS OF THE FABRIC AND THE
ROLL WHICH IS DIPPED IN THE LIQUOR.
 DYEING
THE FOAM PROCESS
A FOAM IS ALLOWED TO COLLAPSE ON A TEXTILE
SUBSTRATE, THE THIN LIQUID FILM GETS DEPOSITED
ON THE SUBSTRATE.
DYEING
NEW DYEING MACHINARY
RAPID JET DYEING MACHINE
AERODYNAMIC SYSTEM
MICROWAVE DYEING MACHINES
ROTODYE DYEING MACHINE
DYEING

DYEING TECHNIQUES
PAD-DRY-PRESSURE STEAM TECHNIQUE
INVERSE DYEING OF BLENDS
DYEING BY PH SLIDE SYSTEM
LOW TEMPERATURE DYEING
TREATMENT WITH LOW BATH RATIO
DYEING
TREATMENT WITH LOW BATH RATIO

Relationship between Bath Ratio and Production Cost in Reactive Dyeing

DYEING
SHIFT TO SOLVENT PROCESSING

ORGANIC SOLVENT PROCESSING

 INORGANIC SOLVENT PROCESSING
PRINTING

AS THERE IS NOT MUCH CONSUPTION

OF UTILITY AND CHEMICALS AS
COMPARED TO BLEACHING & DYEING,
STILL THERE IS A SCOPE FOR SAVINGS.
PRINTING

PRINTING MACHINES
MAINTENANCE OF PRINTING MACHINE IS VERY
IMPORTANT AS FAR AS QUALITY AND ECONOMY
IS CONCERNED.

ONLINE WASHING SYSTEM

FLY CHANGE
PRINTING
FAST ACTING CATALYSTS

USE OF FAST ACTING CATALYSTS INSTEED OF CONVENTIONAL

CATALYST , LEADS TO RAPID OR MILD CURE. THE PROCESS
PERMITS MILD CURING ON DRYING CANS AT 95-100°C
FOR 40-60 SEC.

EMULSION BASED THICKENERS

PARTIAL SUBSTITUTION OF ALL AQUEOUS THICKENING

BY EMULSION BASED THICKENING ESPECIALLY IN THE CASE
OF BLOTCH MOTIFS IS ANOTHER WAY OF CONSERVING
THERMAL ENERGY IN TEXTILE PRINTING.
PRINTING
 FOAM TECHNIQUE

HAS GREAT POTENTIAL IN TEXTILE PRINTING FROM

THE POINT OF:
 ENERGY SAVING AND
 ELIMINATION OF THE USE OF CONVENTIONAL THICKNERS

SILICATE PAD-BATCH METHOD

THIS METHOD HAS A HUGE POTENTIAL TO SAVE ENERGY

PRINTING
ONE STEP FIXATION
BY THE USE OF SELECTED COMBINATION OF DISPERSE AND
REACTIVE, ONE STEP FIXATION IS POSSIBLE.

EG. DISPERSOL PC-PROCION PC DYESTUFFS

OR PROCILENE PC LIQUID DYES

TRANSFER PRITNTING
THIS IS A COMPLEATELY DRY PROCESS.NO
PRETREATMENT IS REQUIRED.SO, 100% SAVING OF
ENERGY AND WATER.
PRINTING

ELIMINATION OF CURING

IT IS SUGGESTED TO INCORPORATE NOMINAL QUANTITIES

OF MINERAL ACID E.G. SULPHURIC ACID IN THE PRINT
PASTE WITH THE SALT OF PARAENT MINERAL ACID AND THIS
EFFECT THE LOCALISED CARBONISATION BY DRYING OF
THE GOODS RATHER THAN BY CURING AND THUS TO
CONSERVE SUBSTANTIAL ENERGY IN BRASSO PRINTING STYLE.
FINISHING
THE MAXIMUM AMOUNT OF ENERGY IN FINISHING IS
CONSUMED IN REMOVING WATER FROM THE
TEXTILES.STENTER CONSUMES MORE THAN
60 PERCENT OF THE TOTAL PROCESSING ENERGY
REQUIREMENTS.
FINISHING
FOR PROPER UTILIZATION OF HEAT ENERGY EMPLOYING
THE STENTER MACHINE VARIOUS POINTS CAN BE CONSIDERED

 Stenter exhaust should be run only when necessary as heat loss in

exhaust is as high as 30 per cent.
 It is unnecessary wastage of energy to keep stenter machine
waiting for fabric.
 Machines where exhaust is completely shut off, can give
saving of 30 percent and above.
 In the latest type of stenter machines, micropmcessor
controlled devices are installed with control parameters
like finished width, moisture content, rate of overfeed, etc.
 It should be ensured that the fabric leaving the
finishing machine is not overdried.
PRINTING
NEW FINISHING TECHNIQUES
VACUUM EXTRACTION
THE WATER CONTENT OF THE FABRIC IS REDUCED AND AIR IS
DISPLACED FROM THE INTERSTICES OF THE FIBRE.

RASH AGEING
DRYING AND POLYMERISATION CAN BE COMBINED.
FOR DESIRED RESULTS 155-160°C TEMPERATURE FOR 35-40
SECONDS WAS OPTIMUM.
NONCONVENTIONAL SOURCES OF
ENERGY

SOLAR ENERGY

BIO-GAS IN TEXTILE INDUSTRY

References:

Sanjay K. Chaudhari, JTA Jan - Feb 2001

Khan r. a, Colouage, 1988
Taraporewala K S and Shah S A, MMTI 1990
Chinta S K, Wasif A I, Vijar Kumar M C, Colourage 1993
Pande S H, Chattopadhay S N, Pan N C and Day A, Colourage 1994
?