Energy Conservation in Textile Wet Processing

Wet processing occurs at various stages in the creation of textiles, including pre-treatment (e.g. cleaning, bleaching and heat setting), dyeing, printing and finishing.Wet processing uses relatively homogeneous processes. It is the most energy-intensive aspect of textile production, accounting for 75 to 85 percent of plant utility costs.

While plants that perform wet processing often require energy for dry processes, space conditioning (i.e. heating, cooling and ventilation) and other needs, this post focuses   on the energy use and management in wet processing.

Energy management is an influential determinant of a plant’s energy performance. Best practices in energy management are characterized by a high level of commitment, awareness, organization and action in support of energy management.A major focus of an energy management plan is performing a self-assessment to identify energy savings opportunities.Establishing an energy management plan and implementing cost-effective energy conservation opportunities result in increased profitability and competitive advantage for the manufacturer.Equally significant, reduction in energy use can produce significant environmental improvements.The basic requirements for an Energy management Program in textile wet processing

1. Management Commitment

2. Review Of Utility Rate Structure And Purchasing Strategy
3. Self Assessment To Identify And Calculate Energy Savings
4.Quantify Unit Costs for Energy

5.List The Major Energy Consuming Equipment in the Plant
6. Identify Savings Opportunities and Gather Relevant Data
7.Calculating Cost Savings and Implementation Costs
8. Continued Feedback And Analysis
Establishing an Energy Management Program : A Guide Book
Water and Energy saving Solutions in Textile dyeing and printing
Recent Developments in Textile Dyeing
Energy conservation inTextile Manufacturing : UNIDO Report
Energy conservation textile Wet processin an Indian experience
Improvement of Resource Efficiency and Environmental Performance

Energy Efficiency and Environment Management

Energy Conservation
K-C filtration offers energy savings.(A Look at What's Going On In The Industry): An article from: Nonwovens Industry
ISO 14000: Issues & Implementation Guidelines for Responsible Environmental Management

Textile Knitting

Knitting Fundamentals
Yarn Requiremnt for Knitting

History of Knitting
Introduction to knitting
covers following topics

• Introduction
• Weft knitting
• Warp knitting
• Binding elements in weft knitting
• Stitches
• Basic weft knitted structures
• Plain knit structure
• Rib knitted structures
• Purl knitted structures
• Interlock knitted structures
• Comparison between simple weft knitted and woven fabrics

V-Bed Machine Technology
Covering following Topics

• Machine architecture / construction
• Needle technology: latch needles
• Needle technology: compound needles
• Knitting action
• Needle-bed technology
• Sinker technology
• Feeder technology
• Cam technology
• Stitch size and stitch cam adustment
• Take-down technology
• Roller take-down systems
• Take-down systems
• Needle selection
• Stitch transfer
• Racking
• Machine control (introduction)

V-bed machine fabric structure and patterning

• Following topics are covered
• Introduction
• Knitted fabrics
• Use of the four basic structures
• Patterning
• Tuck loops
• Multiple tucks
• Floats
• Inlay yarn
• Racking
• Limitations of racking
• Loop transfer racking
• Pattern racking
• Knitted loop transfer
• Yarn feeding techniques
• Doubling
• Jacquard knitting
• Quality control in V- bed knitting
• Positive feed in V-bed machines
• Knitting calculations;: A cross-indexed text book of practical problems in flat and rib knitting on the interrelation of yarn number; diameter; needles ... ... miscellaneous problems; and so on

Circular Knitting Technology
A presentation on circular knit fabrics click here
Covering following topics

• Machine architecture / construction
• Needle technology
• Knitting action
• Sinker technology
• Relative displacement
• Feed technology
• Cam technology
• Needle selection
• Take-down technology
• Machine control
• Circular Knitting fabric Structure and Patterning
• Circular Knitting Redefined: Leave Those Straight Needles Behind

Quality Control In Circular Knitting

• Covers following topics
• Introduction
• Quality
• Yarn quality
• Yarn count (tex) and twist (turns/cm)
• Yarn lubrication
• Lubrication of filament and spun yarn
• Other quality checks in winding
• Quality control in knitting: initial machine settings
• Loop length control
• Yarn input tension
• Positive feed
• Loop length control on jacquard machines
• Dropped stitches and holes
• Needle lines
• Fabric barre
• Lint control
• An introduction to the stitch formations in warp knitting: Technological and structural rudiments in simple and basic stitch formations

Warp Knitting Machine Technology

• Following Topics are covered
• Machine architecture / construction
• Needle technology
• Knitting element displacements
• Tricot knitting
• Raschel knitting
• Yarn feeding technology
• Knitting element displacement technology
• Guide bar shog, overlap and underlap
• Take-down technology
• Machine control
• Graphical Representation of Warp Knit Structures
• Weft Knitting Fundamentals
• Graphical representation of Weft Knit Structures
• Quality control in Weft Knitting
• An Introduction to Weft Knitting (Merrow Technical Library: Textile Technology; 11)

Yarn tension, cam forces and robbing back
Watch Videos :- Gearhart Socks Knitting

Read Books :-
A refrence Book on Kniiting Technology
Wet Processing of 100% Cotton Knitted Fabrics
Dyeing and finishing of knitted goods from filament yarns
wet processing of knits
CIRCULAR FRAMES, CIRCULAR AND FLAT KNITTING MACHINES, FANCY KNITTED FABRICS.

Textile Wet Processing

An Introduction to textile Wet Processing

Fibers ,Yarns , threads ,Woven and knit textiles goods cannot be processed into apparel and other finished textile products until they have passed through several water-intensive wet processing stages. Wet processing enhances the appearance, durability, and serviceability of textiles by converting undyed and unfinished goods, known as gray or greige goods, into finished consumers’goods. Also collectively known as  dyeing and fmishing, wet processing has been broken down into four stages:

1.Fabric or yarn  preparation
To ensure that the textile has the right physical and chemical properties to enable it to be coloured or finished.
EXAMPLE:
Desizing, Singeing, Scouring, Bleaching etc.
2.Coloration or dyeing
To provide the textile with colour either for aesthetic reasons or for some functional purpose determined by the end-use of the product.
EXAMPLE:
Yarn Dyeing ,Fabric Dyeing
3.Printing
Textile printing is the process of applying colour to fabric in definite patterns or designs.
EXAMPLE
Roller printing, cylinder printing, or machine printing ,Stencil printing ,Screen-printing ,Digital textile printing 4.Finishing.
To provide the textile with the properties that the end-use demands and which have not already been provided by any earlier processes.
EXAMPLE:
Crease resistance, dimensional stability, stain resistant ,Water Repellency, Flame Repellency, Antisoiling finish etc.
These stages, involve treating gray goods with chemical baths and often require additional washing,rinsing, and drying steps. Note that some of these steps may be optional or repeated depending on the style-quality- type  of textile items being manufactured.

Read More
Water and textile Wet Processing -1
Historical notes on the wet-processing industry
AATCC Garment Wet Processing Technical Manual
A workbook for pollution prevention by source reduction in textile wet processing
Trainer's Workbook on Cleaner Production in Textile Wet Processing

Automation in Dye House

Automation is a need for todayAutomation today’’s competitive market where quality, cost and availability is playing major role.
In today today’s scenario quality , quantity and service are the most critical requirements for the servival of textile industry . The cost of production is increasings rapidly but the costs such as  labour cost, raw material cost, power cost, etc. are not in our control. The biggest question for a textile dyer today  is to increase the productivity and reduce the production cost.
The options for increasing productivity and reducing cost of production are
􀂾Reduction in Labour cost
􀂾Reducing Utility cost by power saving
􀂾Value enhancement by Quality improvement
􀂾Increasing output Through state of art machinery
􀂾Improving efficiency and service through managemant systems

All these can be possible only by implementing Automation

What is Automation?
Monitoring and controlling of any process with the help of latest technologies like software, ladder and logic controls, Robotics, ERP system and incorporating central computer is called Automation.
 
WHY AUTOMATION

􀂾Achieve more with less.
􀂾Elimination of human error
􀂾Consistency of product
􀂾Minimize Energy consumption
􀂾Easy diagnosis of fault
􀂾Reduction in Resources(Chemicals ,water , energy etc.)
􀂾Reduce manpower.
􀂾Data collection and consolidation.
􀂾Effective application for Complex tasks
􀂾Trending and Report generation.
􀂾Reduction in Effluent
􀂾Improve Safety and Health.
􀂾Reduce breakdowns.
 Dyehouse Management Manual
The very important area for Automation is the dyeing process, because it involves lot of minute parameters which are very  critical. Even in milligrams variation of recipe can change the shade of  the fabric. All the parameters for dyeing like temperature, pressure,water level, water flow, circulation and time of treatment are  most important.
Automation of the dyeing process can improve the producti productivity by controlling the above parameters very accurately.

Automation in textile dyeing and printing means one or more (or all) of the following steps:
a. Programmable process control (by microprocessors) of the machinery;
b. Dissolving and dispensing of the dyes, pigments and chemicals in a central colour kitchen;
c. Computer-controlled weighing of solid material with automatic stock control and the printing of recipe and process cards;
d. Colour measurement, computerized colour matching;
e. Central computer (network), computerized management system

Criteria for selection of  an Automation System

It is very important to identify the need and the feasibility of the system to be automated.The production cost, the complicity of the machines, the utility requirement of the machines, quality parameters of the products are most important factors to consider while planning for Automation.
Select The System which has

1.Flexibility
2.Ease of Programming.
3.Adaptability to change.
4.Expandability
5.Enhanceability of  function.
6.Ruggedness in system.
7.Service Back up.
Learn More
Different types of  automation systems
Seven Steps to Superior Color Control in the Dyehouse
Need of Automation
The Textile Management System