Supported by EIE/04/246/S07.38678

Benchmarking and Energy management Schemes in SMEs

Measure List Textile Industry

Process-related Improvement Opportunities

To download this list in Excel format click here

Energy Efficiency Method	Short Description/ procedure stage
1. Replace rinsing baths with jets	Dyeing: Achieve to use lower quantities of liquid, less heating and cooling.
2. Use vacuum extraction before washing and/or drying	Drying/washing: This quite new technique is used to extract as much water from the fabric
3. Modify burners in stretchers, dryers and singeing machines	Adjustment or replacement can result in energy saving.
4. Increase drying capacity with IR, NIR, HF and RF (radio frequencies)	Drying: Use radio frequencies to increase the capacity of stretchers and for preliminary drying.
5. Use ultrasonic techniques for washing or dyeing textiles	Drying: Use ultrasonic waves to improve bath washing and dyeing process.
6. Utilise modern, energy-efficient spinning, knitting and weaving equipment	Energy saving methods over all stages of productivity
7. Prevent air intake in the steamer	Dyeing: Keep the splits in steamer as small as possible to reduce the steam consumption
8. Replace oil-fuelled equipment with gas-fuelled models	Increase the participation of gas-fuelled plants because of its energy efficient characteristics
9. Utilise ink-jet printing technology	This trend in the textile sector is used particularly for shorter rung lengths
10. Automate water intake in dyeing equipment	Accomplishment of significant water saving
11. Place washer’s wash tubs in counter-flow	Accomplishment of significant water saving
12. Optimize the use of basic materials and additives	Reduction of consumption of basic materials
13. Change to new, more advanced fibres.	New fibers are subjected to less treatment due to product characteristics
14. Use bio-gas from waste water purification	The bio-gas from waste water can generate heat used in the productivity cycle.
15. Utilise targeted extraction	Utilize local extractor hood
16. Minimize rejects by purchasing high quality basic material	Energy conservation method
17. Minimize rejects by improving composition control	Energy conservation method
18. Reduce the liquid ratio in discontinuous equipment by means of suppression elements and/or by optimising piling	Dyeing: Energy conservation method to reduce water and energy amounts.
19. Increase fabric speed in wide washer	Optimize fabric speed while keeping the washing results
20. Optimise temperature setting on wide washer	Software material can be used for these purposes
21. Reduce chemical doses in the wide washer	Software material can be used for these purposes
22. Modify rinse ratio in wide washer to between 1:3 and 1:5	Optimize the wide washing process
23. Monitor the rinsing process during washing using sensors (including conductivity meters)	Monitor the process can result in time, water and energy savings
24. Control extractor air based on moisture content and/or underpressure in stretcher or dryer	Drying: Limit the amount of extracted air, by measuring the moisture content.
25. Control temperature setting in stretcher and dryer with a pyrometer	Drying: Install pyrometer to measure the temperature of the fabric- attire significant information on the over-drying
26. Use wet-in-wet treatment	Drying: Wet-in-wet treatment means integrating two sub-processes, making the intermediate drying stage redundant
27. Ensure proper steam conditioning in the steamers	An important method in order to avoid a detrimental effect on the temperature and moisture content of the fabric
28. Optimise the rotation speed of spinners, twisters and rinsers	It is proven that equipment is more energy consumption at high speed
29. Take measures to reduce rejection and over-processing	Do necessary adjustments to optimize the procedure in total
30. Optimise computer program for equipment control	Use specific software material to monitor the operation of the equipment
31. Control the liquid level in discontinuous dyeing processes	Energy conservation method
32. Measure the moisture content of fabric in drying processes	Drying: Measure the fabric moisture to adjust the machine operation
33. Reduce air extracted from stretchers by means of valve settings in extraction channels	Adjust the valves to regulate the quantity of air
34. Reduce dyeing periods by measurement and control (including pH and conductivity)	Dyeing: By using pH meters, adjust time periods of dyeing
35. Reduce temperature of rinsing water	Energy saving method
36. Use dyes with a higher fixation degree	The fixated dyes need less energy and water than the non-fixated ones
37. Installation of control unit	Batch dyeing: Install control units to monitor the batch dyeing procedure
38. Hot water consumption reduction in jigger	Batch dyeing: In the jigger is measured an significant energy conservation
39. Usage of vacuum dewatering systems	Batch dyeing: Very significant water conservation - recommended mechanical systems
40. Avoid over-temperature over open dyeing machines	Batch dyeing: Recommended temperature for a safer operation is 95^0
41. Usage of MA techniques	MA (Minimum Application) techniques share the characteristic of applying less moisture to the fabric
42. Prefer closed machines	Thermal loss reduction
43. Usage of low add-on liquor application systems/reduction of volume capacity	Energy saving method
44. Adoption of dispensive systems	Adopting dispensing systems where the chemicals are dispensed on-line
45. Avoid washing at temperatures >950 in open/semi-closed machines	Avoid washing at temperatures of 95 °C or more when the washing tanks aren’t perfectly closed.
46. Adaptation of water flows	Increased productivity method
47. Use mechanical drying	Drastic moisture reduction prior to thermal drying
48. Control Steamers	Monitor steam extraction
49. Minimise energy consumption in stenter frames	Drying: Reduce water content of the incoming fabric
50. Minimise energy consumption in stenter frames	Maintaining exhaust-humidity between 0.1 and 0.15 kg water/kg dry air
51. Minimise energy consumption in stenter frames	Install heat recovery systems
52. Minimise energy consumption in stenter frames	Fit insulating systems
53. Minimize energy consumption in stenter frames	Ensure optimal maintenance of the burners
54. Reuse heat of discharge from stretchers and dryers	Recycling of heat- used not in large scale.
55. Reclaim residual heat from the dyeing and washing equipment	Use a heat exchanger and collect the heat in order to reuse in the washing phase.
56. Avoid overflowing conditions	Batch dyeing: Energy saving method.

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