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Efficiency Measures
Overview of textile production processes and energy efficiency measures for machineries,
technologies and equipment researched on by the SET project team to develop an Energy
Saving and Efficiency Tool (ESET)
Table of contents
Table of contents ....................................................................................................................2
Acknowledgments ..................................................................................................................3
1 Executive summary .........................................................................................................4
2 - Introduction ....................................................................................................................... 5
3 - Textile production processes ....................................................................................... 7
4 - Energy in the textile industry.................................................................................... 11
4.1 - Energy use in yarn production, main factors affecting energy consumption and
reference values ...................................................................................................................... 12
4.2 - Energy use in fabric production, main factors affecting energy consumption and
reference values ...................................................................................................................... 14
4.3 - Energy use in finishing, main factors affecting energy consumption and reference
values ...................................................................................................................................... 16
Disclaimer
The sole responsibility for the content of this publication lies with the authors. It does not
necessarily reflect the opinion of the European Union or of any of the organization
mentionedunless explicitly stated. Neither the EASME nor the European Commission are
responsible for any use that may be made of the information contained therein.
This document is updated until December 2014, however contents are simplifield and
provided for general information purposes only. By no mean the contents provided in this
document shall be considred exausitve.
Legal and or official documentation released at EU level or the national legislation shall be
consulted.
Acknowledgments
The SET project (contract n IEE/13/557/SI2.675575) is co-funded by the IEE Intelligent Energy
Europe programme of the European Union managed by EASME, the European Commission
executive agency for SMEs.
www.euratex.eu/set
3/73
1 Executive summary
This document is the report of the work performed by the SET project team coordinated
by CITEVE for the purpose of 1) defining and structure the targeted basic textile
production processes, 2) collecting energy efficiency measures for machineries,
technologies and equipment, and 3) identify newly developed processes with potential to
replace traditional ones with gains in energy consumption.
Three levels of textile processes classification were defined. The first level corresponds to
the three value creation steps defined early in the project Spinning (later replaced by
Yarn Production), Fabric Production and Finishing. The second level (phase) provides
more specific processes or steps inside the three main groups and in the third level (subphase) are listed the most significant machineries, equipments or very specific processes,
in terms of energy use.
A list of 117 cross-cutting measures and 105 specific energy efficiency measures were
created, mostly based on Hasenbeigi [1](specific measures) and ARTISAN project (cross
cutting measures). This is far above the targeted 60 specific and 60 cross cutting. Each of
the identified specific measure was linked to a process or machinery listed on the second
or third level of process classification, respectively.
Newly developed processes can be found as measures for energy savings in Energy
Efficiency Measures chapter (e.g. Microwave Dyeing).
For the collection of these measures, teams were defined as in the following table:
Table 1 Composition of the SET project teams collecting energy efficiency measures
Team
1
2
Type of measures
Specific
Specific
Process
Yarn production
Fabric production
Specific
Finishing
Cross cutting
Organizations
DITF (DE) / IVGT (DE) / Centexbel (BE)
TMTE (HU)/ IVGT (DE)
CITEVE (PT) / IVGT (DE)/ Inotex ATOK
(CZ)
ENEA (IT)
2 - Introduction
The need of reduce / rationalize energy consumption has assumed huge importance
during the last years with the growth of energy prices, environmental constraints and, in
some countries, legal obligations.
The rational use of energy calls for a broad application of energy efficiency technologies in
the various industrial sectors where energy is wasted. One of these energy intensive
industrial sectors to be considered to improve efficiency through the introduction of
energy conservation technologies and techniques is the textile industry.
Over the past decade there has been a decrease in the energy consumption of this industry
in the European Union (figure 1), which is mainly due to the economic situation but also
some improvements in energy efficiency. However, there is still room for further
improvements since the situation varies significantly within the EU members.
12.000
10.000
8.000
6.000
4.000
2.000
0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
Year
Figure 1 Energy consumption on Textile and Leather industries in EU (Source: Eurostat 29/10/2014)
The representation of energy costs, compared to the total costs of the company, in the case
of a vertical textile company, based in a study in Portugal, is estimated to be between 15%
to 25% [2]. Developing an understanding of how energy is used in a textiles plant is an
important component of improving the energy management. Knowing what the major
end-users of energy in a plant are helps to identify what priorities need to be for energy
efficiency improvements.
Energy-efficiency improvement opportunities in the textile industry include opportunities
for process specific improvements, which includes retrofit/process optimization as well as
the complete replacement of the current machinery with state-of-the-art new technology,
and opportunities for cross cutting improvements in steam and/or thermal fluid boilers,
compressed air, conditioning, lighting, electrical motors and pumps, etc.
The expression Yarn production has replaced the original term Spinning in the first level of
classification in order to avoid repetition of terms in different levels, since Spinning was also
being used in the second level of classification.
Process
(Level 1)
Phase
(Level 2)
Subphase
(Level 3)
Opening for cotton (1.1.1)
Cards (1.1.2)
fibers (1.2)
Extruders (1.3.1)
Winding (1.3.2)
Ring-spinning (1.4.1)
Compact spinning (1.4.2)
Spinning (1.4)
crimping (1.7)
Process
(Level 1)
Phase
(Level 2)
Subphase
(Level 3)
Sectional warping (2.1.1)
Beam warping (2.1.2)
Draw-warping (2.1.3)
Beaming machines (2.1.4)
Sizing/slashing (2.1.5)
Indigo warp dyeing lines (2.1.6)
Rapier weaving (2.2.1)
Projectile weaving (2.2.2)
Air jet weaving (2.2.3)
Weaving (2.2)
Fabric production (2)
Knitting (2.4)
Process
(Level 1)
Phase
(Level 2)
Pretreatment (3.1)
Dyeing (3.2)
Finishing (3)
Printing (3.5)
Subphase
(Level 3)
Carbonising (3.1.1)
Singeing (3.1.2)
Crabbing (3.1.3)
Desizing (3.1.4)
Bleaching batch (3.1.5)
Continuous Bleaching (3.1.6)
Yarn washing (3.1.7)
Rope washing (3.1.8)
Open-width washing (3.1.9)
Solvent washing (3.1.10)
Milling/fulling (3.1.11)
Yarn Mercerising (3.1.12)
Fabric Mercerising (3.1.13)
Yarn continuous dyeing (3.2.1)
Fabric continuous dyeing (3.2.2)
Autoclaves (3.2.3)
Hank (3.2.4)
Jet (3.2.5)
Overflow (3.2.6)
Winch becks (3.2.7)
Jiggers (3.2.8)
Other dyeing machines (3.2.9)
Centrifugal hydro-extractors (3.3.1)
Stenter (3.3.2)
Yarn Dryers (3.3.3)
Fabric Dryers (3.3.4)
Other Dryers (3.3.5)
Tumblers (3.3.6)
Mechanical finishing (3.4.1)
Decatising (3.4.2)
Calenders (3.4.3)
Singeing machines (3.4.4)
Knitwear ironing presses (3.4.5)
Tumblers (3.4.6)
Sanfor (3.4.7)
Other finishing machines (3.4.8)
Top and yarn printing (3.5.1)
Flat screen printing (3.5.2)
Rotary screen printing (3.5.3)
Inkjet Printing (3.5.4)
Other printing machines (3.5.5)
the European Union (28 countries) for textile and leather industries in 2012.
Solid Fuels
Petroleum
1%
8%
Electricity
40%
Natural Gas
46%
Renewables
0%
Heat
5%
Figure 2 - Breakdown of energy consumption by type of energy for the textile and leather industries in the
European Union on 2012 (source: Eurostat 29/10/2014)
Finishing processes have higher energy consumption than the yarn and fabric production.
Most of the energy used on those processes is thermal. Yarn and Fabric production mostly
use electricity as power source of the machines motors.
The following points present a slightly more detailed description of energy consumption
in each of the first level textile production processes: Yarn Production, Fabric Production
and Finishing, main variables affecting that consumption and reference values (when
available) for the consumption of each subphase.
Phase
(Level 2)
Subphase
(Level 3)
Triggers
Preparation for
cotton (1.1.3)
Speed of machine
Relevant product
groups and
benchmarks for
relevant triggercombinations
Opening of natural fibers
and manmade fiber bales
Speed of machine
Speed of machine
Speed of machine
Speed of machine
Speed of machine, yarn
count
Speed of machine
Speed of machine
Phase
(Level 2)
Subphase
(Level 3)
Worsted cards (1.2.5)
Triggers
Relevant product
groups and
benchmarks for
relevant triggercombinations
Speed of machine
Semi-worsted cards
(1.2.6)
Woollen cards (1.2.7)
Speed of machine
Speed of machine
wool (1.2.9)
Preparation for
(1.2.10)
Finishers (1.2.11)
Roving frames for
worsted yarn (1.2.12)
Production of
man-made
filaments and
fibres (1.3)
Speed of machine,
temperature
Speed of machine
Winding (1.3.2)
Speed of machine
Ring-spinning (1.4.1)
Speed of machine,
temperature
Speed of machine,
temperature, number of
nozzles
(1.4.2)
Winding, reeling
Speed of machine
Extruders (1.3.1)
Compact spinning
Spinning (1.4)
Speed of machine
Variable, depending on
the type of machine
Yarn count, Speed of
machine
Yarn steaming,
setting,
(1.6.1)
Cotton
Phase
(Level 2)
Subphase
(Level 3)
moistening and
Heat-setting machines
coating (1.6)
(1.6.2)
Moistening machines
(1.6.3)
Yarn coating machines
(1.6.4)
Texturing,
bulking and
crimping (1.7)
Texturing machines
(1.7.1)
Bulking and crimping
machines (1.7.2)
Doubling machines
Doubling and
(1.8.1)
twisting (1.8)
Twisting machines
(1.8.2)
Triggers
Relevant product
groups and
benchmarks for
relevant triggercombinations
Polyester
current industry trend is for high added-value goods and multi-line, small-volume
production based on advanced systems such as computer-controlled pattern making
mechanisms. Therefore, a potential tendency for increased energy consumption
should be taken into account [6].
The factors (triggers) which are most affecting the energy consumption for a
determined textile process in fabric production are presented in the following table, as
well as reference values of energy consumption (when available) for the processes
defined in the previous chapter.
Table 6 Triggers and relevant product groups and benchmarks for Fabric Production
Phase
(Level 2)
Subphase
(Level 3)
Sectional warping
(2.1.1)
Triggers
Repeatable patterns in
warp direction,
multicolor yarns
Draw-warping (2.1.3)
Relevant product
groups and
benchmarks for
relevant triggercombinations
Clothing, home textiles,
technical textiles with
patterns
High-speed production
for uncolored warps
Technical textile warp
Beaming machines
(2.1.4)
Sizing/slashing (2.1.5)
Tubular fabrics
Projectile weaving
(2.2.2)
Weaving (2.2)
Air jet weaving (2.2.3)
Phase
(Level 2)
Preparation for
knitting (2.3)
Knitting (2.4)
Subphase
(Level 3)
Circular weaving (2.2.6)
Narrow fabrics weaving
(2.2.7)
Beam warping (2.3.1)
Sectional warping
(2.3.2)
Circular knitting
machines (2.4.1)
Flat knitting machines
(2.4.2)
Warp knitting machines
(2.4.3)
Knitting (2.4)
Relevant product
groups and
benchmarks for
relevant triggercombinations
Triggers
Tubular fabrics
Filtersacks
Tape and fabrics <30cm
For warp knitting only
Repateable patterns
Clothing
High production, thick
yarn diameter, spacer
fabrics
Phase
(Level 2)
Subphase
(Level 3)
Carbonising (3.1.1)
Pretreatment
(3.1)
Singeing (3.1.2)
Crabbing (3.1.3)
Desizing (3.1.4)
Triggers
Speed of machine,
temperature field
Speed of gassing,
machine type, type of
fiber
Velocity of machine,
specific weight of fabric
g/m2, temperature and
pressure of the rollers
Liquor Ratio (L.R.) in
discontinuous
processes, type of fiber,
machine type
Bleaching batch
(3.1.5)
Continuous
Bleaching (3.1.6)
Pretreatment
(3.1)
Process temperature,
type of fiber, machine
type
Liquor Ratio (L.R.), Bath
Rope washing (3.1.8) temperature, type of
fiber, machine type
Yarn washing (3.1.7)
Relevant product
groups and
benchmarks for
relevant triggercombinations
[1]
Desize unit - Desizing Energy requirement
(GJ/tonne output): 1,0 3,5
[1]
Kier - Scouring/Bleaching Energy requirement
(GJ/tonne output): 6,0 7,5
Jig/ winch - Bleaching Energy requirement
(GJ/tonne output): 3,0 6,5
[1]
Open width range Scouring/bleaching Energy requirement
(GJ/tonne output): 3,0 7,0
Phase
(Level 2)
Subphase
(Level 3)
Open-width washing
(3.1.9)
Solvent washing
(3.1.10)
Milling/fulling
(3.1.11)
Yarn Mercerising
(3.1.12)
Pretreatment
(3.1)
Fabric Mercerising
(3.1.13)
Yarn continuous
dyeing (3.2.1)
Dyeing (3.2)
Fabric continuous
dyeing (3.2.2)
Triggers
Process temperature,
type of fiber, machine
type
Relevant product
groups and
benchmarks for
relevant triggercombinations
[1]
5 hot standing tanks before
bleaching 7,5 GJ/tonne
4 tanks, fully counter flow,
with heat exchanger before
bleaching- 2,8 GJ/tonne
5 tanks, fully counter flow,
with heat exchanger before
scouring/bleaching- 3,0
GJ/tonne
4 tanks counter flow and 1
cold standing tank before
dyeing 6,6 GJ/tonne
4 hot counter flow and 3
cold individual flow before
printing 10,5 GJ/tonne
4 hot counter flow with
heat exchanger and 3 cold
individual flow before
printing 5,5 GJ/tonne
Type of machine,
velocity of machine,
solvent flow rate, drying
temperature
Type of fiber, machine
type
Process temperature,
type of fiber, machine
type
Process temperature,
type of fiber, machine
type
Process temperature,
type of fiber, machine
type
Process temperature,
type of fiber, machine
type
[1]
Continuous/Thermosol Dyeing - Energy
requirement (GJ/tonne
output): 7,0 20,0
Pad/Batch - Dyeing Energy requirement
(GJ/tonne output): 1,5 4,5
[4]
Woven dyeing - average
energy specific
consumption 1235,4
kgoe/tonne
Phase
(Level 2)
Subphase
(Level 3)
Autoclaves (3.2.3)
Hank (3.2.4)
Jet (3.2.5)
Overflow (3.2.6)
Winch becks (3.2.7)
Dyeing (3.2)
Water extraction
and drying (3.3)
Triggers
Relevant product
groups and
benchmarks for
relevant triggercombinations
[4]
Yarn dyeing - Average
energy specific
consumption 1070,2
kgoe/tonne
[1]
Hank - Dyeing - Energy
requirement (GJ/tonne
output): 10,0 16,0
[1]
Jet - Dyeing - Energy
requirement (GJ/tonne
output): 3,5 16,0
[4]
Dyeing of knitted fabricAverage energy specific
consumption 671,5
kgoe/tonne
Jiggers (3.2.8)
[1]
Jig - Dyeing - Energy
requirement (GJ/tonne
output): 1,5 7,0
Other dyeing
machines (3.2.9)
[1]
Beam - Dyeing - Energy
requirement (GJ/tonne
output): 7,5 12,5
Stenter (3.3.2)
[1]
Stenter - Drying - Energy
requirement (GJ/tonne
output): 2,5 7,5
Stenter - Heat Setting Energy requirement
(GJ/tonne output): 4,0 9,0
[1]
Hank - Drying - Energy
requirement (GJ/tonne
output): 4,5 6,5
Phase
(Level 2)
Subphase
(Level 3)
Tumblers (3.3.6)
Mechanical finishing
(3.4.1)
Decatising (3.4.2)
Calenders (3.4.3)
Singeing machines
(3.4.4)
Finishing
machines (3.4)
Knitwear ironing
presses (3.4.5)
Tumblers (3.4.6)
Sanfor (3.4.7)
Other finishing
machines (3.4.8)
Top and yarn
printing (3.5.1)
Printing (3.5)
Triggers
Specific weight of fabric
g/m2, moisture of the
fabric at the entrance,
type of fiber, drying
temperature fields
Specific weight of fabric
g/m2, moisture of the
fabric at the entrance,
type of fiber, drying
temperature fields
Type of fiber, drying
temperature fields,
speed of machine
Machine type, speed of
machine
Speed of machine, type
of fiber, steam pressure
Temperature and
pressure of the rollers,
speed of machine
Speed gassing, machine
type
Temperature and
pressure of the rollers,
speed of machine
Type of fiber, drying
temperature fields
Specific weight of fabric
g/m2, type of fiber,
drying temperature
fields, machine type
Variable, depending on
the type of machine
Relevant product
groups and
benchmarks for
relevant triggercombinations
[1]
Steam cylinders - Drying Energy requirement
(GJ/tonne output): 2,5 4,5
Velocity of machine
Drying temperature
fields, machine type
Rotary screen
printing (3.5.3)
Drying temperature
fields, machine type
Inkjet Printing
(3.5.4)
Other printing
machines (3.5.5)
[4]
Printing - Average energy
specific consumption 411,1
kgoe/tonne
[1]
Rotary Screen - Printing Energy requirement
(GJ/tonne output): 2,5 8,5
Process / Phase
(Level 1/ Level 2)
Yarn production (1)
Spinning Preparation for cotton fibers (1.1)
Spinning Preparation for wool fibers (1.2)
Production of man-made filaments and fibres (1.3)
Spinning (1.4)
Winding, reeling and covering (1.5)
Yarn steaming, setting, moistening and coating (1.6)
Texturing, bulking and crimping (1.7)
Doubling and twisting (1.8)
Fabric production (2)
Weaving preparation (2.1)
Weaving (2.2)
N of measures
Process
optimization
Newly developed
processes
2
20
2
2
1
2
3
7
1
4
1
Process / Phase
(Level 1/ Level 2)
Preparation for knitting (2.3)
Knitting (2.4)
Finishing (3)
Pretreatment (3.1)
Dyeing (3.2)
Water extraction and drying (3.3)
Finishing machines (3.4)
Printing (3.5)
N of measures
Process
optimization
Newly developed
processes
3
11
20
18
1
-
2
4
1
-
Measure applicability
N of measures
2
10
8
17
17
10
10
24
3
16
The list of energy efficiency measures are presented in the following tables, together
with a short description of the measure, the applicable process, reference values of
energy savings (fuel and electricity) and an approach of the required investment cost
and the resulting payback period.
Measure (Action)
Efficient Spindle Oil
Measure description
Use energy efficient spindle
oil
Installation of electronic
Installation of electronic
Roving end-break stop-motion
Roving end-break stopdetector instead of pneumatic
motion detector
system
New machine can be
High speed carding machine
applied for Card
Optimum oil level in spindle
Optimum oil level
bolsters
Optimum oil level in spindle
Optimum oil level
bolsters
Replacement of lighter
spindle in place of
Replacement spindle
conventional spindle in Ring
frame
Replacement of lighter
spindle in place of
Replacement spindle
conventional spindle in Ring
frame
Synthetic sandwich tapes for
Synthetic sandwich tapes for
Ring frames
Ring frames
Synthetic sandwich tapes for
Synthetic sandwich tapes for
Ring frames
Ring frames
Optimization of ring diameter
with respect to yarn count in
Optimization of ring diameter
ring frames
Applied for
Fuel Savings
Payback
period
(years)
Ring-spinning (1.4.1 )
no
no
3,2
MWh/year/machine
138/roving
machine
Cards (1.1.2)
no
yes
77000/card
<2
ing machine
Ring-spinning (1.4.1 )
no
yes
Compact spinning
(1.4.2)
no
yes
Ring-spinning (1.4.1 )
no
23 MWh/year/ring
frame
10500/ ring
8
frame
Compact spinning
(1.4.2)
no
23 MWh/year/ring
frame
10500/ ring
8
frame
Ring-spinning (1.4.1 )
no
Compact spinning
(1.4.2)
no
415-525/
ring frame
415-525/
ring frame
Ring-spinning (1.4.1 )
no
1230/ ring
frame
<1
1-2
1-2
2
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
23
Measure (Action)
Optimization of ring diameter
with respect to yarn count in
ring frames
False ceiling in Ring spinning
section
False ceiling in Ring spinning
section
Installation of energy efficient
motor in ring frame
Installation of energy efficient
motor in ring frame
Installation of energyefficient excel fans in place of
conventional aluminum fans
in the suction of Ring Frame
Installation of energyefficient excel fans in place of
conventional aluminum fans
in the suction of Ring Frame
The use of light weight bobbins
in Ring frame
The use of light weight bobbins
in Ring frame
High- speed ring spinning
frame
Installation of soft starter on
motor drive of Ring frame
Measure description
Applied for
Fuel Savings
Payback
period
(years)
2
Compact spinning
(1.4.2)
no
Ring-spinning (1.4.1 )
no
Compact spinning
(1.4.2)
no
Ring-spinning (1.4.1 )
no
Compact spinning
(1.4.2)
no
Ring-spinning (1.4.1 )
1230/ ring
frame
6,3-18,83
MWh/year/motor
6,3-18,83
MWh/year/motor
15001700/motor
15001700/motor
no
5,8-40 MWh/year/
ring frame
150-240/
fan
<1
Compact spinning
(1.4.2)
no
5,8-40 MWh/year/
ring frame
150-240/
fan
<1
Ring-spinning (1.4.1 )
no
Compact spinning
(1.4.2)
no
500/ ring
frame
500/ ring
frame
Ring-spinning (1.4.1 )
no
Ring-spinning (1.4.1 )
no
10,8 MWh/year/ring
frame
10,8 MWh/year/ring
frame
10%-20% of ring
frame energy use
1-5,2
MWh/year/ring
frame
Installation of Variable
Installation of Variable
Frequency Drive in Autocorner
Frequency Drive
machine
331,2
MWh/year/plant
2-4
2-4
<1
<1
2
15000/plant
<1
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
24
Measure (Action)
Intermittent mode of
movement of empty bobbin
conveyor in the
Autocorner/cone winding
machines
Modified outer pot in Tow-ForOne (TFO) machines
Optimization of balloon setting
in Tow-For-One (TFO)
machines
Replacing the electrical heating
system with steam heating
system for the yarn polishing
machine
Measure description
Applied for
Fuel Savings
Payback
period
(years)
<1
Intermittent mode of
movement
49,4
MWh/year/plant
Doubling machines
(1.8.1 )
no
4% of TFO energy
use
Doubling machines
(1.8.1 )
no
yes
Heat-setting machines
(1.6.2)
increased 31.7
19,5
tonnes
MWh/year/machine
steam/year/machine
Grinding of Tambour
yes
no
yes
no
yes
<1
Cleaning wastebox
Cleaning nozzle
Fitting of airfree compact on
ringframe
no
no
yes
yes
<1
<1
Ring-spinning (1.4.1 )
no
yes
Relaxation of yarn
850/plant
750/humidif
<1
ication plant
150/card
11,5/spindle
<1
<1
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
25
Payback
Measure (Action)
Measure description
Applied for
Fuel Savings
period
(years)
Replace gripper
Replace gripper
Sizing/slashing (2.1.5)
Sizing/slashing (2.1.5)
6000/beamin
g machine
<2
300/loom
<2
1000/loom
<2
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
26
Payback
Measure (Action)
Measure description
Applied for
Fuel Savings
period
(years)
reduce 1/3 of
compressed air
consumption per
loom
800/loom
<2
30000/loom
<3
Weaving (2.2)
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
27
Measure (Action)
Measure description
Applied for
Fuel Saving
Electricity
Savings
Combine Preparatory
Treatments in wet
processing
up to 80% of
Preparatory
Treatments energy
use
Cold-Pad-Batch
pretreatment
up to 50% of
up to 38% of
pretreatment
pretreatment fuel use
electricity use
Bleaching batch
(3.1.5)
30000 -93000
saving (net annual
operating savings
(average per plant)
which includes
energy and nonenergy savings)
Use of Counter-flow
Current for washing
41% - 62% of
washing energy use
Investment
Cost
Payback
period
(years)
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
28
Measure (Action)
Installing automatic
valves in continuous
washing machine
Measure description
The losses at nips are
considerable. Hence, it is
important to cover them as well
as the hot tanks. Any fitted covers
should be easily removable to
allow quick access.
Automatic stop valves which link
the main drive systems of
machines to water flows can save
considerable amounts of energy
and water by shutting off water
flow as soon as a stoppage
occurs.
Installing heat recovery
equipment on a continuous
washer is usually a simple but
very effective measure since
water inflow and effluent outflow
are matched and this eliminates
the need for holding tanks.
A reduction in live steam
pressure can prevent steam
breakthroughs, thus improving
heat transfer efficiency in direct
steam heating applications.
Similarly, reducing steam
pressure in closed coils will have
take advantage of the fact that
lower pressure steam has higher
latent heat content.
Applied for
Fuel Saving
Open-width
washing (3.1.9)
36%
Open-width
washing (3.1.9)
Yes
Open-width
washing (3.1.9)
Yes
Open-width
washing (3.1.9)
Yes
Electricity
Savings
Investment
Cost
Payback
period
(years)
< 0,5
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
29
Measure (Action)
Introducing Point-of-Use
water heating in
continuous washing
machine
Enzymatic scouring
Measure description
Point-of-use gas-fired water
heaters can be used to enable
processes to be run
independently of plant central
boiler systems. This means that
boiler and distribution losses
associated with centralized
systems can be eliminated.
Electrically interlock the exhaust
hood fans with the forward
movement of the water tray, as
the fans usually have to remove
the fumes generated during the
washing phase only.
Interlock the cooling blower
motor with the singeing
machines main motor, thereby
saving energy.
The interlocking of blower
motors with the machines main
motor can be implemented in
fabric shearing machines.
Rinsing steps after peroxide
bleaching can be reduced with
enzymatic peroxide removal
(normally only one rinsing
step with hot water is
necessary).
With the use of enzymes the
alkaline scouring process can
be replaced.
Applied for
Open-width
washing (3.1.9)
Fuel Saving
Electricity
Savings
<50%
Investment
Cost
Payback
period
(years)
High
Yarn Mercerising
(3.1.12)
12,3
MWh/year/machine
<0,5
Singeing (3.1.2)
2,43
MWh/year/machine
< 0,5
Mechanical
finishing (3.4.1)
2,43
MWh/year/machine
< 0,5
Bleaching batch
2780 GJ/year/plant
(3.1.5)
Bleaching batch
Yes
(3.1.5)
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
30
Measure (Action)
Measure description
Applied for
Fuel Saving
Autoclaves
(3.2.3)
Autoclaves
(3.2.3)
Electricity
Savings
26,9
MWh/year/machine
Investment
Cost
2400 /machine
Payback
period
(years)
1,5
2% in steam
consumption per
kilogram of dyed
yarn
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
31
Measure (Action)
Measure description
Applied for
Fuel Saving
4 GJ/tonne
fabric/plant
Yes
Electricity
Savings
6,3 kWh/tonne
fabric
Investment
Cost
Payback
period
(years)
4/tonne of fabric
Chemical
Dispensing System:
117500 -698000
;
Dye Dissolving and 1,3 - 6,2 ;
Distribution:
4 - 5,7 ;
78500 - 313750; 3,8 - 7,5
Bulk Powder
Dissolution and
Distribution:
59500 - 470500
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
32
Measure (Action)
Measure description
Applied for
Fuel Saving
Electricity
Savings
Investment
Cost
Payback
period
(years)
Dyeing (3.2)
Yes
44700 117600/system
1-5
Dyeing (3.2)
112000 166000/system
1,3 - 3,6
Fabric
continuous
dyeing (3.2.2)
16,3 GJ/tonne of
dyed fabric
953000/ system
1,4 - 3,7
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
33
Measure (Action)
Discontinuous dyeing
with airflow dyeing
machine
Installation of VFD on
circulation pumps
Dyebath Reuse
Measure description
Applied for
Fuel Saving
Electricity
Savings
Payback
period
(years)
149500 284000/machin
e
up to 60% of
machine's fuel use
138
MWh/year/plant
Investment
Cost
1800/plant
<1
18800 26600/dye
machine
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
34
Measure (Action)
Measure description
Applied for
Fuel Saving
Electricity
Savings
Investment
Cost
Payback
period
(years)
<1
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
35
Measure (Action)
Measure description
Applied for
Fuel Saving
Other dyeing
machines
(3.2.9)
96% reduction
compared to beam
dyeing
Dyeing (3.2)
Yes
Electricity
Savings
90% reduction
compared to beam
dyeing
Investment
Cost
Payback
period
(years)
353000/
machine
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
36
Measure (Action)
Measure description
Applied for
Fuel Saving
Dyeing (3.2)
4580 GJ/year/plant
Dyeing (3.2)
Yes
Dyeing (3.2)
Yes
Jiggers (3.2.8)
27 - 91 kg
steam/hour
Electricity
Savings
Investment
Cost
Payback
period
(years)
130000/plant
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
37
Measure (Action)
Insulation of un-insulated
surface of Autoclave
Measure description
A new generation of jiggers
with a variable liquor ratio has
been developed in order to be
able of processing. These
jiggers make use of a heat
exchanger, allowing the heat to
be removed and applied
elsewhere in the plant. In each
passage, the length of the cloth
is measured, so extra fabric at
the end of the batch can be
avoided.
Installation of a heat exchanger
and surrounding equipment like
water tanks and pumps for
recovering heat from hot waste
water as a heat source.
All the hot surfaces should be
insulated, including those of the
main vessel, air vent tank, heat
exchanger and water circulation
piping. Water-resistant, easypaste type insulation material is
usually recommended.
Improving process control either
mannually through better staff
training or using specific
software.
Capture the heat from the rinse
water and use it for pre-heating
the incoming water for the next
hot rinse.
Applied for
Fuel Saving
Jiggers (3.2.8)
26% reduction
compared to
conventional jigger
Autoclaves
(3.2.3)
554 MJ/batch
product
Autoclaves
(3.2.3)
15 MJ/batch product
Dyeing (3.2)
10% -12%
Dyeing (3.2)
Electricity
Savings
Investment
Cost
34500 -74500
Payback
period
(years)
< 0,5
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
38
Measure (Action)
Measure description
Applied for
Fuel Saving
Dyeing (3.2)
Yes
Dyeing (3.2)
10%
Water extraction
and drying (3.3)
Yes
Other Dryers
(3.3.5)
Yes
Other Dryers
(3.3.5)
Yes
Electricity
Savings
Investment
Cost
Payback
period
(years)
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
39
Measure (Action)
Avoid Intermediate
Drying
Avoid Overdrying
Measure description
There are systems which allow
finishes to be applied wet on
wet to avoid intermediate drying
between processes.
Control the speed of the drying
cylinders so that the equilibrium
moisture level of the fibre is not
exceeded.
Careful scheduling of fabric
batches arriving at the cylinders
to reduce idling time, and make
cylinders extra wide to allow two
batches of narrow fabric to run
side by side.
Avoid steam leaks performing
adequate maintenance.
The steam heated dryer, which is
used to dry dyed acrylic yarn
skeins, can be replaced by a radio
frequency dryer.
Switching the drying of bobin
products from dry-steam
heaters to low pressure (LP)
microwave drying.
Applied for
Fuel Saving
Water extraction
and drying (3.3)
Yes
Other Dryers
(3.3.5)
Yes
Other Dryers
(3.3.5)
Yes
Electricity
Savings
Investment
Cost
Payback
period
(years)
Other Dryers
(3.3.5)
Yarn Dryers
(3.3.3)
35300 saving/plant
Yarn Dryers
(3.3.3)
Yes
157000/plant
107 kWh/tonne
yarn
392000/plant
<3
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
40
Measure (Action)
Conversion of Thermic
Fluid heating system to
Direct Gas Firing system
in Stenters and dryers
Measure description
Replace thermal fluid heaters by
direct gas firing systems. In the
new system, air is directly heated
by gas fired burners and the
required temperature is obtained
by circulating hot air through the
chambers.
This measure provides savings
on fuel consumption with the
reduced heat losses and on the
electricity required for pumping
the thermic fluid.
Use mechanical water extraction
equipment such as mangles,
centrifuges, suction slots and air
knives; or contact drying using
heated cylinders.
Control the speed of the stenter
so that the equilibrium moisture
level of the fibre is not exceeded.
Perform proper scheduling to
minimize machine stops and
close exhausts during idling
times.
Proper insulation of stenter
envelopes reduces heat losses to
a considerable extent.
Applied for
Fuel Saving
Stenter (3.3.2)
11000 GJ/year/plant
Stenter (3.3.2)
Stenter (3.3.2)
Yes
Stenter (3.3.2)
Yes
Stenter (3.3.2)
20% of stenter
energy use
Electricity
Savings
120
MWh/year/plant
Investment
Cost
39200/plant
Payback
period
(years)
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
41
Measure (Action)
Optimize Exhaust
Humidity
Efficient burner
technology in Direct Gas
Fired systems
Measure description
In order to optimize drying rates
and energy use, air flows through
the oven (and therefore the
exhaust rate) must be carefully
controlled, analysing the
moisture content of the exhaust
air.
Heat-recovery air/air: Uses
exhaust air heat to heat up fresh
air supplied to the stenter
Heat-recovery air/water: Uses
exhaust air heat to heat up
service water for wet finishing
(for example washing, dyeing,
and bleaching.)
Optimized firing systems and
sufficient maintenance of burners
in direct gas-fired stenters can
minimize methane emissions,
which is important because
methane emissions from burners
greatly determine actual burner
capacity. Stenters should receive
general maintenance by
specialized companies at regular
intervals. There should also be
routine checking of the burner air
inlet for blockings by lint or oil,
cleaning of pipe works to remove
precipitates and adjusting of
burners by specialists.
Applied for
Fuel Saving
Stenter (3.3.2)
20 - 80% of stenter
energy use
Stenter (3.3.2)
Yes
Stenter (3.3.2)
30% of stenter
energy use
Stenter (3.3.2)
Yes
Electricity
Savings
Investment
Cost
60400 361000/system
Payback
period
(years)
1,5-6,6
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
42
Measure (Action)
Measure description
Applied for
Fuel Saving
Electricity
Savings
11% of stenter
electricity use
Investment
Cost
Payback
period
(years)
moisture humidity
controllers: 15700
172500;
dwell time controls:
63000 314000
moisture
humidity
controllers:
1,5 - 5 ;
dwell time
controls: 4 6,7
Stenter (3.3.2)
Finishing (3)
3250 GJ/year/plant
4000/plant
Finishing (3)
1,3 - 2 GJ/tonne
fabric
800 - 12500
Finishing (3)
258000 / system
1-6
NOTE: The energy efficiency measures highlighted in bold are referent to newly developed processes.
43
Measure (Action)
Measure description
Applied for
Fuel Saving
Reconsideration of
It is an economic measure
electric supply contract.
Reconsideration of
thermal supply contract
It is an economic measure
/ cost of used
combustibles.
Shifting of energivorous
processes towards
lower price time slots.
0% (no energy
saving, but there
may be economic
saving)
0% (no energy saving, but
there may be economic
saving)
Reduction of
peak power
Use of work-shifts.
Reduction of
peak power
Removal of covering /
impediments from
heating appliances and
air conditioners.
Heating/Air
conditioning
from 0 to 1% of
factory thermal
consumption
Heating/Air
conditioning
from 0 to 20% of
thermal
consumption in
shed building with
window frames in
polycarbonate and
where the heat is
only used for
building heating
Adoption of high
efficiency window
frames.
Electricity Savings
from 0 to 1% of factory
electrical consumption
Investment Cost
Payback
period
(years)
Negligible
Immediate
Negligible
Immediate
Slight
Immediate
Low/Medium
Immediate
Slight
Short Short/Medium
- Medium
Low/Medium
Medium
44
Measure (Action)
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
Heating/Air
conditioning
from 0 up to 50%
of thermal
consumption in
case of heat used
only for building
heating
Limitation of heated /
conditioned volumes (it
can be sufficient to
spread a nylon sheet).
Heating/Air
conditioning
up to 3% of factory
thermal
consumption
up to 2% of factory electric
Low - Low/Medium
consumption
Medium Variable
Heating/Air
conditioning
Variable,
A typical value is <
= 1% of factory
thermal
consumption
Variable
A typical value is 1,5% of
factory electrical
consumption
immediate
Heating/Air
conditioning
Variable
< = 1% of factory
thermal
consumption
Variable
< = 1% of factory electrical Slight
consumption
immediate
Variable
< = 1% of factory electrical Null
consumption
immediate
Variable
< = 1% of factory
electrical consumption
immediate
Set thermostats to
minimum for comfort
(20C in winter and
25C in summer).
Guarantee closed
passages between
acclimatized and non
acclimatized areas.
Use heat/cooling only
when area is occupied.
Clean and effective
heaters/coolers. Verify
dirt deposition in all
heat transfer surfaces.
Heating/Air
conditioning
Heating/Air
conditioning
Variable
< = 1% of factory
thermal
consumption
Variable
< = 1% of factory
thermal
consumption
Medium/High
Null
Negligible
Medium Medium/Long
45
Measure (Action)
Measure description
Applied for
Adoption of
sunbreakers / curtains.
Heating/Air
conditioning
Adoption of high
efficiency electric
engine.
Electric motor
Adoption of inverters
for electric motor.
Adjustable-speed drives
better match speed to load
requirements for motor
operations, and therefore
ensure that motor energy use
is optimized to a given
application.
Electric motor
Fuel Saving
Electricity Savings
from 0 to 1% of factory
electrical consumption
(energy savings related to
lower use of the airconditioning)
from 0 up to 10% of
factory electrical
consumption in case of
obsolete engines
2% - 60%
Investment Cost
Payback
period
(years)
Low
Short/Medium
High
Medium Medium/Long
Medium
46
Measure (Action)
Adoption of motor
management plan.
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
47
Measure (Action)
Maintenance of motors.
Rewinding of motors.
Proper motor sizing.
Power factor
correction.
Measure description
The purposes of motor
maintenance are to prolong
motor life and to foresee a
motor failure.
In some cases, it may be costeffective to rewind an existing
energy-efficient motor,
instead of purchasing a new
motor.
Applied for
Electric motor
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
Electric motor
Electric motor
The power factor can be
corrected by minimizing idling
of electric motors (a motor
that is turned off consumes no
energy), replacing motors
with premium-efficient
Electric motor
motors, and installing
capacitors in the AC circuit to
reduce the magnitude of
reactive power in the system
(U.S. DOE, 1996).
48
Measure (Action)
Measure description
Minimizing voltage
unbalances.
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
The typical
payback
period for
voltage
controller
installation on
lightly loaded
motors in the
U.S. is 2,6
years (U.S.
DOE-IAC,
2006)
Electric motor
Reduction of demand
throught reduction of
compressed air
production pressure.
Reduction of leaks in
compressed air pipes
and equipment.
Applied for
Compressed air
from 0 to 1% of electrical
consumption if the
compressed air is used
improperly for cleaning
reasons
from 0 to 0,1% in other
cases
Null
Immediate
Compressed air
up to 20% of compressed
air system energy use
Low
Short Short/Medium
49
Measure (Action)
Installation of
compressed air
accumulation tanks.
Recovery of heat from
compressors.
Install low-cost
solenoid valves on air
supply lines to
individual machines.
Switch off compressed
air supply as soon as
machine is switched off.
Use lowest air intake
temperature possible in
compressors. Duct air
intake to ensure coolest
possible and/or precool it.
Check on correct
pressure setting
regularly to reduce the
demand.
Replace pneumatic
tools by electrical tools
to reduce the demand.
Do not use compressed
air for cleaning
operations. Use of
vacuum cleaner instead
of compressed air.
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
Compressed air
about 0%
Low - Low/Medium
Short Short/Medium
Compressed air
up to 20% of compressed
air system energy use
Medium
<1
Compressed air
Variable
< = 1% of electrical
consumption
Low
Short
Low/Medium
<5
Compressed air
< = 1% of electric
consumption
Null
immediate
Compressed air
< = 1% of electric
consumption
Low/Medium
Short
Compressed air
Variable
< = 1% of electrical
consumption
Negligible
immediate
50
Measure (Action)
Maintenance of
compressed air plant.
Monitoring of
compressed air plant.
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
51
Measure (Action)
Adoption of electronic
condensate drain traps
(ECDTs) for
compressed air plant.
Maximizing allowable
pressure dew point at
air intake in
compressed air system.
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
52
Measure (Action)
Measure description
Applied for
Fuel Saving
Electricity Savings
up to 3% of compressed
air system energy use
Implementing adjustable
speed drives in rotary
compressor systems has
saved 15% of the annual
compressed air system
energy consumption
Investment Cost
Payback
period
(years)
Medium
Variable
Variable
53
Measure (Action)
Maintenance of
pumping systems.
Measure description
Applied for
Inadequate maintenance
lowers pump system
efficiency, causes pumps to
wear out more quickly and
increases costs. Better
maintenance will reduce these
problems and save energy.
Proper maintenance includes
the following (Hydraulic
Institute, 1994; U.S. DOE,
1999):
Replacement of worn
impellers, especially in caustic
or semi-solid applications.
Bearing inspection and
Pumping
repair.
systems
Bearing lubrication
replacement, once annually or
semiannually.
Inspection and replacement
of packing seals.
Inspection and replacement
of mechanical seals.
Wear ring and impeller
replacement.
Pump/motor alignment
check.
The largest opportunity is
usually to avoid throttling
losses.
Fuel Saving
Electricity Savings
2% - 7% of pumping
electriccity use
Investment Cost
Payback
period
(years)
<1
54
Measure (Action)
Monitoring of pumping
systems.
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
Monitoring in conjunction
with operations and
maintenance can be used to
detect problems and
determine solutions to create
a more efficient system.
Monitoring can determine
clearances that need be
adjusted, indicate blockage,
impeller damage, inadequate
suction, operation outside
preferences, clogged or gasfilled pumps or pipes, or worn
out pumps. Monitoring should Pumping
include:
systems
Wear monitoring
Vibration analyses
Pressure and flow
monitoring
Current or power
monitoring
Differential head and
temperature rise across the
pump (also known as
thermodynamic monitoring)
Distribution system
inspection for scaling or
contaminant build-up
55
Measure (Action)
Reduction of demand
for pumping systems.
Measure description
The objective of any control
strategy is to shut off
unneeded pumps or to reduce
the load of individual pumps.
Remote controls enable
pumping systems to be started
and stopped relatively quickly
and accurately, and reduce the
required labor with respect to
traditional control systems.
Holding tanks can be used to
equalize the flow over the
production cycle, enhancing
energy efficiency and
potentially reducing the need
to add pump capacity. In
addition, bypass loops and
other unnecessary flows
should be eliminated. Energy
savings may be as high as 510% for each of these steps
(Easton Consultants, 1995).
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
Pumping
systems
Pumping
systems
Adoption of more
efficient pumps.
Pumping
systems
Pumping
systems
2% - 10% of pumping
electricity use
Correcting for pump
oversizing can save 15%
to 25% of electricity
consumption for pumping
(on average for the U.S.
industry) (Easton
Consultants, 1995).
<1
56
Measure (Action)
Measure description
Applied for
Fuel Saving
Electricity Savings
Pumping
systems
Pumping
systems
Investment Cost
Payback
period
(years)
57
Measure (Action)
Avoiding throttling
valves for pumping
systems.
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
up to 8% of pumping
electricity use
< 0,5
Pumping
systems
58
Measure (Action)
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
Fan systems
Minimizing pressure in
fun systems.
Fan systems
Fan efficiency.
Proper fan sizing.
Adjustable speed drives
(ASDs) for fan systems.
Temperature, moisture,
molecular weight, elevation,
and the absolute pressure in
the duct or vessel affect the
density of the transporting
gas. A density change may
affect the hardware
requirements for the system.
Variable
< = 1% of electrical
consumption
Low
Short
Fan systems
Fan systems
Fan systems
Fan systems
1-5%
14% - 49% of fan system
electricity use
59
Measure (Action)
Measure description
Applied for
Electricity Savings
Investment Cost
2% of fan system
electricity use
Payback
period
(years)
1- 3 years
Lighting
from 0 to 2% of factory
electrical consumption
Slight
<2
Lighting
from 0 to 3% of factory
electrical consumption
Short
from 0 to 5% of factory
electrical consumption
from 0 to 5% of factory
electrical consumption
Variable
A typical value is 1,1% of
factory electrical
consumption
Medium Medium/High
Medium
Variable
Variable
Slight
immediate
Lighting
Lighting
Lighting
Fuel Saving
Variable
< = 1% of factory electrical Variable
consumption
Short/Medium
60
Measure (Action)
Measure description
Applied for
Lighting
Replace magnetic
ballasts with electronic
ballasts.
Optimization of plant
lighting (lux
optimization) in
production and nonproduction
departments.
Adoption of dimmer to
reduce the use of
artificial light.
Fuel Saving
Electricity Savings
Variable
A typical value is 1,5% of
factory electrical
consumption
Investment Cost
Payback
period
(years)
Low
Short
Lighting
Lighting
Reduction of steam
production pressure.
Steam systems
up to 2% of factory
thermal
consumption
Null
Immediate
Installation of steam
accumulation tanks.
Steam systems
about 0%
Low - Low/Medium
Immediate
61
Measure (Action)
Measure description
Applied for
Fuel Saving
5%
up to 3% of
thermal
consumption
up to 1% of electric
consumption
from 0 to 4% of
factory thermal
consumption (in
Italy)
and up to 20% in
disadvantaged
backgrounds
Electricity Savings
Investment Cost
Payback
period
(years)
Low - Low/Medium
2 - 4 years
Variable
1 years
Medium/High
Medium
Improvement of
insulation of water /
steam pipes.
Steam systems
Adoption of high
efficiency boilers /
steam generators.
Steam systems
Condensates recovery
in steam system.
Steam systems
up to 5%
Variable
1 years
Steam systems
0%
(no energy savings,
but efficiency at the
country level and
economic saving
for the company)
High
Medium/Long
Installation of
cogeneration plant.
62
Measure (Action)
Reduce excess
combustion air to
minimum by CO2/O2
measurement.
Maximise completeness
of combustion by
Soot/CO measurement.
Maintain boiler
cleanliness (soot/scale)
by monitor for rise in
flue gas temperature.
Repair (replace) boiler
and feedwater tank
insulation.
Replace steam traps
with sensor controlled
magnetic valves
(Condensate output on
demand with minimum
loss of fresh steam.).
Insert valves to isolate
"periodic-use" items in
steam system.
Remove/isolate "deadlegs" and redundant
pipework of steam
distribution system
Measure description
Electricity Savings
Investment Cost
Payback
period
(years)
Applied for
Fuel Saving
Steam systems
on average 2,3% of
factory thermal
consumption
Low
<1
Steam systems
< = 1% of factory
thermal
consumption
Low
<1
Steam systems
< = 1% of factory
thermal
consumption
Low
Short
Steam systems
6% - 26% of boiler
energy use
Low/Medium
Short
Steam systems
on average 1,5% of
factory thermal
consumption
Medium
Medium
Steam systems
< = 1% of factory
thermal
consumption
Low/Medium
Medium
Steam systems
< = 1% of factory
thermal
consumption
Low/Medium
Medium
63
Measure (Action)
Eliminate uneconomic
hot standby periods,
maintain heat supply
only if absolutly
necessary.
Demand matching for
steam generation.
Measure description
Applied for
Fuel Saving
Steam systems
Variable
A typical value is
1,1% of factory
thermal
consumption
Electricity Savings
Investment Cost
Slight
Payback
period
(years)
Short
<2
64
Measure (Action)
Maintenance of steam
system.
Optimization of boiler
blowdown rate.
Measure description
Applied for
Steam systems
Fuel Saving
up to 10% of boiler
energy use
Electricity Savings
Investment Cost
Payback
period
(years)
The
establishment
of a
maintenance
schedule for
boilers has an
average
payback time
of 0,3 years
(U.S. DOE-IAC,
2006).
Steam systems
Steam systems
Steam systems
The use of
heat from
boiler blow
down on
average has
payback
period of 1,6
years (U.S.
DOE-IAC,
2006).
65
Measure (Action)
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
On average
leak repair has
a payback
period of 0,4
years (U.S.
DOE-IAC,
2006).
Reduction of
distribution pipe leaks
in steam plant.
Steam systems
Vacuum
systems
Variable
< = 1% of factory electrical Low
consumption
Short
Vacuum
systems
Medium/Long
66
Measure (Action)
Use dedicated vacuum
systems in machines
with low work regime
or geografically offset
from central system.
Applies to machines
with frequent changes,
variable workhours
and/or far from
centralized system. if all
machines suffer from
such variancy,
dedicated systems are
more efficient than
centralized ones.
Adoption of solar
thermal collector.
Replacement of fossil
fuels with renewable
fuels.
Replacement of
electrical heater with
fire heater.
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Variable
< = 1% of factory electrical Variable
consumption
Vacuum
systems
from 0 to 4% of
thermal
consumption for
building heating
0%
(no energy savings,
but efficiency at the
country level and
economic saving
for the company)
from 0 to 1% of
overall thermal
consumption
Payback
period
(years)
Variable
Low
Short
Variable
Variable
Variable
Variable
67
Measure (Action)
Measure description
Applied for
Fuel Saving
0%
(no energy savings,
but efficiency at the
country level and
economic saving
for the company)
Installation of
trigeneration plant.
Switch off the machines
and turn off the lights
during the lunch break.
Establish Energy
Monitoring and Energy
Management System.
Electricity Savings
Variable
Investment Cost
High
Payback
period
(years)
Long
Immediate
Variable
Varible
Medium/High
68
Measure (Action)
Raise awareness of
energy saving in all
workers.
Reduce the amount of
ventilation by control
optimization with a
timer switch and/or
occupancy sensor.
Measure description
Analyse the relation between
consumption and production
output. You can do this using
the SESEC-Benchmark Tools.
In general the energy
consumption consist of a fixed
part (like heating of buildings,
lighting of offices) and a
variable part, depending on
the utilization of machines. A
high fixed part may be
reduced. A curve which
increases more than linear
might hint some productionplanning optimizations
potentials. It might be
necessary to have a look at the
departments seperately.
Train all staff to operate
manual controls, to watch for
energy saving opportunities,
use posters, switch-offand
save-it stickers as a tool of
good housekeeping.
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
Variable
< = 1% of electrical
and thermal
consumption
Variable
< = 1% of electrical and
thermal consumption
Slight
Varible
< = 1% of electrical
and thermal
consumption
Low/Medium
Short
Variable
< = 1% of factory electrical Low
consumption
Medium
69
Measure (Action)
Use free-cooling
whenever possible.
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
5% - 10% of boiler
energy use
Payback
period
(years)
Medium
Preheating water
Steam systems
<2
Replacement of nozzles
Heating/Air
conditioning
31
1310/humidification
MWh/year/humidification
plant
plant
<1
Installation of VFD
Pumping
systems
20
850/humidification
MWh/year/humidification
plant
plant
<1
Fan systems
55,5 MWh/year/fan
<1
500/fan
70
Measure (Action)
Installation of VFD on
Humidification system
fan motors for the flow
control
Installation of VFD
on Humidification
system pumps
Energy efficient control
system
for humidification
system
Energy conservation
measures
in Overhead Travelling
Cleaner (OHTC)
Energy efficient blower
fans
for Overhead
Travelling Cleaner
(OHTC)
Improving the Power
Factor of
the plant (Reduction of
reactive power)
Replacement of
ordinary 'V-Belts' by
Cogged 'V-Belts'
Measure description
Applied for
Fuel Saving
Electricity Savings
Investment Cost
Payback
period
(years)
Installation of VFD
Fan systems
18-105 MWh/year/fan
1450-6660/fan
1-2
Installation of VFD
Pumping
systems
35 MWh/year/
humidification
plant
5460/humidification
plant
2,7
50
5615MWh/year/humidification 9380/humidification
plant
plant
2-3,5
Energy conservation
measures
5,3-5,8 MWh/year/OHTC
140-750 OHTC
0,5-2,5
2 MWh/year/fan
77/fan
<1
24,1 MWh/year/plant
2540/plant
1,8
1,5 MWh/yar/belt
9,4/belt
<1
Fan systems
71
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7 - Reference
[1] Hasanbeigi, A., 2010. Energy-Efficiency Improvement Opportunities for the Textile
Industry. Berkeley, CA: Lawrence Berkeley National Laboratory
[2] CITEVE, 2012, EFINERG Project, Plano sectorial de melhoria da eficincia
energtica em PME Sector txtil e do vesturio
[3] ITMA 2015, General Regulations and Index of Products
[4] CITEVE, 2012, Competitividade Responsvel Project, Guia de boas prticas para a
eficincia energtica no Setor Txtil e do Vesturio
[5] Renovare Project, 2007, Guia de boas prticas de medidas de racionalizao de
energia (URE) e energias renovveis (ER)
[6] United Nations Industrial Development Organization (UNIDO), 1992. Energy
Conservation in Textile Industry-Handy manual
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