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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.
Major activities in the BEE -SME program are furnished below:
Energy use and technology audit
The energy use technology studies would provide information on technology status, best
operating practices, gaps in skills and knowledge on energy conservation opportunities,
energy saving potential and new energy efficient technologies, etc for each of the sub sector
in SMEs.
Capacity building of stake holders in cluster on energy efficiency
In most of the cases SME entrepreneurs are dependent on the locally available
technologies, service providers for various reasons. To address this issue BEE has also
undertaken capacity building of local service providers and entrepreneurs/ Managers of
SMEs on energy efficiency improvement in their units as well as clusters. The local service
providers will be trained in order to be able to provide the local services in setting up energy
efficiency projects in the clusters
Implementation of energy efficiency measures
To implement the technology up-gradation projects in clusters, BEE have proposed to
prepare the technology based detailed project reports (DPRs) for a minimum of five
technologies in three capacities for each technology.
Facilitation of innovative financing mechanisms for implementation of energy
efficiency projects
The objective of this activity is to facilitate the uptake of energy efficiency measures through
innovative financing mechanisms without creating market distortion
INTRODUCTION
1.1 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.
The main energy forms used in the cluster units are grid electricity, wood, and small quantity
of coal. The electricity is used for power looms, doubling machines, winding machines, hydro
extractors, warping machines and lighting. Wood is used as fuel for boilers, thermic fluid
heaters, and chulhas for hot water generation. The details of annual energy consumption of
a typical unit having a production capacity of 1, 20,000 kg of final product of the cluster are
furnished in the Table 1.1 below:
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.
1.2.1 Specific energy consumption of final product
Specific electrical and thermal energy consumption in textile unit depends upon the final
product manufactured in that unit. The electrical and thermal energy consumption of typical
textile unit is 1.65 kWh per kg of final product and 1.20 kg of wood per kg of final product
respectively (includes all colours dyeing in cold water, medium temperature water and high
temperature water)
1.3 Proposed equipment to be upgrade
1.3.1 Description of existing equipment
During energy audit studies in various textile industries in Solapur textile cluster, it was
observed that about 1200 power loom in Solapur Textile cluster. All power looms are of
shuttle type and are too old. These power looms are used for weaving terry towels and bed
sheets.
In the present conventional shuttle looms, it is necessary to pass a shuttle weighing around
half a kilogram through the warp shed to insert a length of weft yarn which weighs only few
grams. The shuttle has to be accelerated rapidly at the starting of picking cycle and also to
be decelerated, stopped abruptly at the opposite end. This process creates heavy noise and
shock and consumes considerable energy. Beat-up is done by slay motion which again
weighs a few hundred kilograms. The wear life of the picker and checking mechanism is also
limited due to heavy shock. Due to the above reasons smooth sequence of weaving is
disturbed which affects the maximum running speed and hence machine production. In multi colour weft insertion, Drop box motion is attached which is also further limits the speed of the
machine. The small weft package in the shuttle requires frequent replenishments and for
each loom stoppage there is a possibility of one defect. The probability of weft way fabric
defects are high to the tune of 70% in shuttle looms. Even in automatic shuttle looms there is
a chance of transfer failures and weft lashing in defects.
1.3.2 Role in process
The power looms are one of the most important equipment in producing of cotton terry
towels and bed sheets. The power looms are used for weaving the dyed yarn to towels and
bed sheets.
1.4 Baseline for existing equipment
Energy consumption for Power loom would depend on following:
• Load on Power loom
• Operational & maintenance practices
1.4.1 Design and operating parameter
Present conventional loom is operated for 12 hours in a day and average electricity
consumption is 34 kWh per day (8.5 kWh per loom for four conventional looms) connected
with 1 HP motor. The average production is 48 kg per day per machine. The power loom
machines are operated in two shifts in a day.
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.
1.5.1 Technological Barriers
The major technical barriers that prevented the implementation of Rapier loom are
• Lack of awareness and information about the rapier loom and its benefit
• Absence of local Rapier loom supplier
• Dependence on local equipment suppliers, whom doesn’t have technical knowledge
about rapier loom and its proper installation
1.5.2 Financial Barrier
Implementation of the proposed project activity requires investment of ` 49.81 lakh per unit.
Such investment is not commonly seen in the cluster units for energy efficiency
improvement. Further, from the business perspective of SMEs, it is more viable, assured,
and convenient to invest on project expansion for improving the production capacity or
quality, rather than make piecemeal investment in retrofit and replace options for energy
savings. In view of this and given the limited financial strength of the textile mills, it is evident
that the owners would not like to take the risk and invest in energy efficiency measures.
However, the financial attractiveness of the project activity may motivate the owners to move
forward in taking up initiatives in energy conservation and efficiency.
1.5.3 Skilled manpower
The non-availability of skilled manpower having awareness about energy efficiency and
related issues in the cluster is one of the major barriers. Lack of skilled manpower for
operation and maintenance of the rapier looms is also one of the major barriers that
prevented the implementation.
1.5.4 Other barrier (If any)
The recent recession in European and other Asian countries and reduction in market trend
for the products in national and international markets was also one of the major barriers for
the proposed technology.
PROPOSED ENERGY EFFICIENT EQUIPMENT
2.1 Detail description of technology
2.1.1 Description of equipment
The rapier looms offer unparalleled versatility when it comes to yarns. From the finest counts
of cotton to the thickest Industrial yarns and can handle anything thrown at its negative
rapier head. The soft-pick gear system enables smooth transition of even highly fancy yarns
like embroidery and slub. The rapier loom is upgrade from shuttle-looms to the world of
modern weaving system and shutte-less weaving. Rapier looms has been designed to
replace the old shuttle looms without any major changes to the existing infrastructure. The
Immediate benefits of selecting rapier looms are
No need for new buildings or any new infrastructure.
• Could fit in place of your current shuttle-looms.
• Configured specially keeping in mind the skills of power-loom operators.
• No special training required for loom operators.
• Immediate reduction of man-power and laborers.
• 20% subsidy under TUFS on our certified looms in addition to State Government
Incentives.
• Step-by-Step consultancy by our engineers to help you upgrade, install & adapt
to new machines.
Speed
The normal speed of the conventional power looms is around 120 RPM, where as in rapier
looms, the speeds upto 220 RPM (actual) can be attained and coupled with high efficiencies
of upto 95%, this machine gives upto 3 times more productivity than the conventional power
looms.
Color Weft Insertion
Rapier looms offers up to 8 Color Pick-at-Will weft insertions, so that weave the fanciest of
fabrics can be attained. The pick-at-will system is computerised and microprocessor
controlled, hence letting the programme sequences of more than 1, 00,000 picks. Such
technological edge will definitely give you an edge in the market.
Start-Mark Prevention System
Rapier looms realises the most delicate need of rapier users to prevent start-marks in
weaving. The custom designed ‘HT-Drive’ motor of the machine supplies more than 150%
torque for the first-pick to successfully prevent the start marks.
Lower per meter Costs
Considering 3 times more productivity with same space and even lesser amount of man
power along with lower power consumption, it is quite obvious that rapier looms can offer
lower production costs compared to conventional power-looms or even rapier-shuttle change
machines. Moreover continuous weft-insertion eliminates the need for investing in pirnwinding
machines or even extra operators.
Lower Maintenance
Due to lower vibrations, there’s less wear-n-tear of rotating components and bearings
resulting in lower maintenance costs. Also, centralised lubrication offered on the looms gives
single-point lubrication for the complete machine, thus further reducing the headaches of
maintenance
Shedding
The rapier loom has the flexibility and can easily add and attach any of the shedding motions
available in the market including:
• Dobby
• Jacquard
• Cam Shedding
• Positive Cam: for Heavy plain fabrics (bolting cloth, tirecord cloth etc.)
• Negative Cam: for light sensitive fabrics
Take-Up
Universal 7-wheel Wretchet-n-Pawl semi-positive take-up is the most widely used and well
established Take-Up system offered in rapiers around the world. The well designed take-up
is capable of handling a weft-density of 4-120 picks per Inch.
Let-Off
The capability of rapier looms to weave any and all kinds of fabrics has been created due to
3 different let-off options available with the machine depending on your fabric.
Ruti-Type
For weavers of regular cotton-fabrics who’ve been used to highly versatile Ruti-Type let-off.
Microprocessor Controller
The heart of the complete control system, this microprocessor is one of the most powerful
control systems offered today for crank-type rapier looms. The system can be programmed
to output any kinds of pick programs. The standard functions include:
• Constant monitoring of weft and warp yarn for breakages Cloth Length Counter
• Pick-programming
• Weft-Controller
Exclusive Feature
For all power loom users, investing in Rapier looms normally require them to erect a
completely new building infrastructure. But, with AWT-250EX, we’re proud to say that we are
the only rapier-loom manufacturer in the world whose machines can fit in the regular ’16-feet
sheds’, thus eliminating the need for any additional investment and hence brings down the
up-gradation costs considerably. In Solapur Textile Cluster units, majority of the units has
power looms, Considering the above facts and benefits of the rapier loom and for reducing
the overall production cost, it is suggested to replace power looms with rapier looms. The
details of production cost per kg in power looms is provided in Annexure 1
2.1.2 Availability of equipment
The Rapier loom suppliers are available in Pune, which is 200 km from Solapur city and M/s
Laxmi Shuttleless loom is also planning to appoint a dealer at Solapur.
2.1.3 Service/equipment providers
The service providers are available in Pune. Details of service providers are given in
Annexure 6.