05-12-2012, 05:53 PM
DETAILED PROJECT REPORT ON AUTO LOOM / RAPIER LOOM (8 Nos.) (SOLAPUR TEXTILE CLUSTER)
1DETAILED PROJECT REPORT.pdf (Size: 1.75 MB / Downloads: 489)
EXECUTIVE SUMMARY
Zenith Energy Services Pvt. Ltd is executing BEE-SME program in Solapur textile cluster,
supported by Bureau of Energy Efficiency (BEE) with an overall objective of improving the
energy efficiency in cluster units.
Solapur textile cluster is one of the largest textile clusters in India; accordingly this cluster
was chosen for energy efficiency improvements by implementing energy efficient
measures/technologies, so as to facilitate maximum replication in other textile clusters in
India.
The main energy forms used in the cluster units are electricity and fuel such as wood and
other biomass product. Electricity is mostly used in power looms, winding machines,
doubling machines, warping machines, hang dyeing machine, blowers, hydro extractor,
small pumps and lighting.
Retrofitting of power looms with rapier/auto looms will reduces the power consumption &
production cost and also increases the rate of production.
Project implementation i.e. installation of eight rapier/auto loom in place of thirty two power
loom will lead to reduction in electricity consumption by 38400 kWh per annum however; this
intervention will not have any effect on the existing consumption pattern of fuel.
ABOUT BEE’S SME PROGRAM
Bureau of Energy Efficiency (BEE) is implementing a BEE-SME Programme to improve the
energy performance in 25 selected SMEs clusters. Solapur Textile Cluster is one of them.
The BEE’s SME Programme intends to enhance the energy efficiency awareness by funding
/ subsidizing need based studies in SME clusters and giving energy conservation
recommendations. For addressing the specific problems of these SMEs and enhancing
energy efficiency in the clusters, BEE will be focusing on energy efficiency, energy
conservation and technology up-gradation through studies and pilot projects in these SMEs
clusters.
INTRODUCTION
About the solapur textile cluster
The products manufactured in Solapur Textile Cluster are cotton terry towels and bed
sheets. The towels and bed sheets are renowned in the country and have good market in
India. The main raw material for the units is cotton yarn, which is procured from local
spinning mills and agents. The cost of energy (electrical and thermal energy) as percentage
of manufacturing cost varies between 8 and 10%.
Majority of the cluster units are of integrated type, where the raw material yarn is processed
in-house to the final product. The energy cost is second to the raw materials cost. Majority of
the units in the cluster are dependent on local/ run of the mill technologies of low end and
with little investment initiatives and technology up-gradation.
Energy performance in cluster
Majority of the industries located in solapur are engaged in manufacturing of towels and bed
sheets. The main energy sources for Solapur cluster units are electricity and fuels such as
Wood & briquettes. The wood and GN husk briquettes are used as fuel for boilers, thermic
fluid heaters and chulhas for hot water generation and electricity is used for operation of
prime movers of doubling machine motors, ID & FD fans, pumps, hank dyeing machine
drives, power loom drives, winding machine motors, etc. Majority of the units in the Solapur
textile cluster are using wood for thermal energy generation due to easy availability and
economical point of view.
Energy cost is around 8 to 10 percent of manufacturing cost in typical manufacturing unit,
out of which the cost of electrical energy works out to 58 percent of the total energy cost and
remaining accounts for thermal energy.
In a typical textile manufacturing unit annual consumption of electrical energy and wood is
1,97,784 kWh and 144 tonnes respectively for average production capacity of 1,20,000 kg of
final product.
Barriers for adoption of proposed equipment
The technology and innovations in SMEs are generally different from that of large firms.
Technology in the SME sector has an increasingly complex or combinative character, most
of the SMEs units in Solapur cluster are labour intensive and utilize local resources. The
SME entrepreneurs are generally not willing to invest in state-or-art technology. Major
barriers in the up-gradation of technology in the cluster are non availability of technology;
distrust on technology supplier, lack of awareness about energy efficiency among small and
medium enterprises, prevents them from adoption of energy efficient technologies.