Case Study Energy Saving in Textiles

by Converting Shuttle loom to Rapier Loom

by

Ravinder & Narender Vannam BEE

2nd Workshop on Best practices in Energy Efficiency in Textile Sector

28 June, 2016- Ahmedabad

Awarded Gold Medal by DST-Dept. of Science &Technology –

Govt. of India and Lockheed Martin - USA

in India Innovation Programme.

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Warp- Weft ( Tana-Bana)

Textile-saving 5

Basic Motions of Loom

Textile-saving 6

Basic Motions of Loom

Textile-saving 7

RAPIER LOOM

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Technology Description • We have designed & developed Updation Kit for converting Shuttle loom to Rapier

Loom.

Save electricity and reduce CO2 emission by 20%

Boost Productivity by

30%

Improves the Quality

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In-Situ upgradation to Rapier Loom.

Can upgrade the Loom without

shifting

No need to remove Looms in

workshed

Less wear & tear / breakages

No down time for setting.

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We have introduced Dwell mechanism.

Rapier stops at end of shed.

Types of Rapiers

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Rapier

Double Flexible

With Dwell

Without Dwell

Single & Rigid

Types of Rapiers • Single Rigid Rapiers are not very popular.

• Double Flexible Rapiers are used in converting Shuttle loom to Rapier Looms.

• Differences of With Dwell & Without Dwell Rapiers are as follows:

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Description With Dwell Without Dwell

1 Crank End to end of Loom , distance 6 inch 12 inch

2 Rapier travel Rapier stops(dwell) at end

of shed

Rapier overtravels outside

shed

3 Speed of Loom, productivity Can be increased Can’t be increased

4 Wear of reciprocating parts Wear is less Wear is more

5 Breakdown Less More

6 Maintenance cost Less Very high

7 Distance between 2 looms No need to shift the existing

Looms

Needs more space. Hence

Looms need to be shifted.

8 Initial cost Marginally More Less

9 Life of Rapier kit 3 years 6 months

Types of Rapiers • Technical Recommendation:

• Hence looking at the advantages of Rapier with Dwell, it is recommended to use the same while upgrading Shuttle loom to Rapier loom.

• Rapier without Dwell is not recommended due to recurring maintenance problems.

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In-Situ upgradation scheme

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In-Situ upgradation scheme

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http://ministryoftextiles.gov.in/sites/default/files/news-mar/index.html#features/3

Developement • Special Cam Mechanism with Dwell

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Wooden Prototype Actual Cam machined on CNC

Video

Technology - benefits • Owner- save approx. 20% energy required in Power loom.

- Increase the productivity by 30%

- Improve Quality of the Fabric due to less stoppages.

• Operator-Reduce noise levels by 10%.

-Improve Ergonomics of machine . Less fatigue on operator.

- Improved safety: Existing Flying shuttle may leads to fatal accidents

- Women can also operate the upgraded Loom & hence empowers the women.

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Technology - benefits • Society-Save Natural Resources like, Wood being

used in Shuttle, Picking Arms.

• This will be cost effective to small players in :

Sircilla, Kadakandla, Warangal-Telangana,

Nagari, Hindupur-AP,

Bhiwandi, Solapur, etc. in Maharashtra, who can’t afford new machines.

• Our Technology will be ray of hope for poor weavers.

• Our solution is ¼ cost of China loom & 1/10 cost of European loom.

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Technology – benefits Energy & Environmental Savings per Powerloom/year

• Energy: 1MWH,

• Saving in Rs: 50,000,

Pollution avoided & hence combating climatic change:

CO2: - 3Ton-GreenHouse Gas-Global warming

SO2: - 16Kg- Acid rain polluting waterbodies

NOx : -8Kg- Carcenogenic Gas Note: 1unit=1KWH=1kg of CO2: =6gm of SO2: =3gm of NOx

1 unit saved = 3 units generated at Thermal power station Reference: pg183 LEED 2011 for India www.igbc.in

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Technology – benefits Operating cost Savings per Powerloom/year

• Electricity cost savings: Rs.50,000/-

• Material cost savings: Pirn winding m/c, operators productivity increase

• Simple payback period: 1.7 year - without subsidy

4-5 months with subsidy • ROI : 59% - without subsidy : 90% with subsidy

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Energy,Pollution & Population

Key levers in the Economy

CO2 = People x GDP x Energy x CO2

Emission person unit GDP Unit Energy

Population Std.of Energy intensity CO2intensity

living Eff.of economy energy source

IP Status

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Key Resources Our Team

Ravinder Vanam:

Qualifications : B.E.Mech. Walchand College of Engineering., MBA, Certified Energy Auditor-BEE,

Professional Experience:

• Worked for 3 decades in Industry

• Did Energy Audits in various Industries resulting in lots of Energy saving.

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Benefits

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Upgrading the powerlooms with our Technology provides considerable cost saving & Environmental benefits over any other alternatives.

Carbon Footprint of Cloth will be reduced drastically.

Trees are saved by avoiding use of Shuttle which is made of fine wood.

By reducing Energy requirement at DSM-Demand side management, Investment in new Power plants will be avoided, saving our precious Natural

resources like , Forests , Water etc.

Awards

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Award ceremony at New Delhi

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NEW update

• the Innovation got included In-situ upgradation pilot scheme w.e.f.1.4.2016

• 50% Central Subsidy for upgradation.

• Further details are yet to come.

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Dr. Kavita Gupta IAS, Textile Commissioner declares In-Situ

Scheme on 28.3.2016 at Bengaluru

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Way forward

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• Got the Innovation included In-situ upgradation pilot scheme.

• Get support from State Govt.

• Funding by Banks.

• Get Green Climatic Funds for GAP funding.

BEE guidance material Paper 4 - Textiles

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BEE guidance material Paper 4 - Textiles

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BEE guidance material Paper 4 - Textiles

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BEE guidance material Paper 4 - Textiles

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Please add details of different types of weaving machines like :

1. Shuttle loom

2. Projectile Loom – ( Sulzer )

3. Rapier loom

4. Air Jet loom

5. Water jet loom etc.

And their Energy efficiency studies.

Thank you! Any Questions ????

Ravinder Vanam – 07036199102

Narender Vanam – 09224973138

bharatrapier@gmail.com

www.srisaitextileconsultancy.webs.com

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