Energy saving in Textile Industry By Converting Shuttle Loom to Rapier Loom

Author:

Mr. Ravinder Vannam - Certified Energy Auditor

Contact: +91-7036199102 | ravinder.vannam@gmail.com

Introduction:

Textile Industry is second largest Employment giving Industry next only to Agriculture, giving employment to approx. 45 million in India, contributing to 2% of GDP and earning 15%Foreign Exchange due to Exports.

Background

Weaving is done on Power Looms.

Presently there are millions of old Shuttle Power Looms in India. Shuttle Looms are very slow, power consuming, noisy and laborious to operate. Shuttle is used to carry warp thread from one end to other in Shuttle Loom. They stop every 2-5 minutes as pirn gets empty. Weaver has to take out the shuttle, change the Pirn in Shuttle, match the color, design & restart the Loom. This leads to Quality problems& loss of Energy, production.

New Modern Rapier are available in Market with high productivity: They are imported from European countries/China etc.

and result in Forex out go & spare parts availability problem. Also they are very costly for the Small /Micro scale operators in India. They consume lot of Energy.

A well designed and developed conversion kit for existing shuttle loom to Rapier Loom i.e. In-Situ upgradation of Power loom.

The advantages of conversion kit are as follows:.

1. Pirn winding process is eliminated.

2. Saving of Energy: 2000GWH /20Lac Looms/Yr=illuminate 5 crore villages=1.6 Lakhs Trees

3. Increase in the productivity by min. of 30%-(depending on type/condition of Loom & yarn.)

4. It reduces the noise level of the machine by 15%.

5. Improve Ergonomics of m/c . Less fatigue on operator.

6. It increases safety of the operator by eliminating flying Shuttle.

7. Improve Quality of the Fabric due to less stoppages& manual interventions.

8. Women can operate the upgraded Rapier Loom and hence, it empowers the women.

Environmental benefits:

1. Reduction in Carbon foot print (GHG-Green House Gas reduction) and hence combating Climatic Change& pollution control. For 20Lac Looms :

   a) CO₂ :5.4Million Tons/yr-CO₂is Green House Gas causing Global warming & Climatic Change

   b) SO₂: Polluting Gas resulting into Acidic Rain:32,000 Tons/Year

   c) NOx-Carcenogenic Gas : 16,000 Tons /year

2. Reduction in Water Consumed in Thermal Power Plants:7 M³/MWH /Loom/yr. =7 Million Liters/20Lakh Looms/Yr

Natural resources like  Wood being used in shuttle is  saved. And hence cutting of the trees is avoided. Approx. 4000Tons 20 Lakh Looms/Yror 8000 M³/20Lakh Looms/Yr

This will be cost effective to small players in Bhiwandi, Solapur, Ichalkaranji, Malegaon, Basmat, Ahmednagar  in Maharashtra State , Sircilla in Telangana State , Nagari, Hindupur in AP etc.

Progress made:

1. New Cam is designed and is made to convert rotary motion of Crankshaft to reciprocating motion of Rapier, including dwell & syncronising with picking & beating motions of Loom .

2. Looms are modified in Solapur-Maharashtra,Sircilla-Telangana State Coimbatore, Kolkatta etc. Working excellently fine. Customers are very Happy.

3. Ministry of Textiles Included in In-Situ upgradation of Powerlooms of SSI Scheme, giving 50 to 90% Subsidy. Telangana Govt. is giving remaining subsidy.

   See website

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

4. Eligible for Green Climate Fund (GCF): http://www.thehindubusinessline.com/todays-paper/tp-news/india-begins-work-on-accessing-100b-climate-fund/article8055794.ece