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Comparative study of energy & space consumption between iDES & conventional dyeing machine

Abstract

The present project depicts less space and energy saving technology of iDES dyeing machine. Due to the small size of the J-box and the absence of the plaiter system the size of the iDES dyeing machine is comparatively smaller than that of the conventional dyeing machine. As there is no plaiter system and inner surface area is less due to the small size of the machine causing less heat loss resulting in lower energy consumption in comparison with the conventional dyeing machine.

This space and energy saving mechanism of iDES dyeing machine has brought a new dimension in the field of dyeing industry in Bangladesh. There are 70 large dyeing industries in Bangladesh with TK 400 crore investments in each factory according to Dyed Yarn Exporters Association, along with that there are more than 800 wet dyeing finishing factories in Bangladesh where this less space and energy saving technology of iDES Dyeing Machine can play a positive role in saving space and energy resulting maximum profit of the factory.

Introduction

This project was held at Eurotex Knitwear Ltd. as they have recently installed iDES dyeing machine of 25 ton capacity production per day and all set to install more iDES dyeing machine. For real time data analysis between iDES dyeing machine and conventional dyeing machine this project was held at Eurotex Knitwear Ltd. as they are among first four industries of Bangladesh to install iDES dyeing machine. During the process, space consumption of every machine was calculated of different capacity to get a precise comparison between iDES dyeing machine and the conventional one. Along with that energy consumption was also calculated using clamp meter keeping the reel speed same, equal pump speed, same value of nozzle having same color shade fabric in equal capacity for both iDES and conventional dyeing machine. The result was positive in every possible way for iDES dyeing machine both in terms of space and energy saving mechanism.

study of energy & space consumption between iDES & conventional dyeing machine

study of energy & space consumption between iDES & conventional dyeing machine

Data analysis for space saving:

Calculation (Space Savings)

Ratio of space occupied by the conventional machine to that of iDES dyeing machine (Ratio) = Area of conventional dyeing machine ÷ Area of iDES dyeing machine.

study of energy & space consumption between iDES & conventional dyeing machine

 

So, area occupied by Conventional Dyeing Machine: Area occupied by iDES Dyeing Machine = 1.4: 1.00

study of energy & space consumption between iDES & conventional dyeing machine

We can say that conventional machine needs 1.4 times more space compared to that of iDES dyeing machine. It is an approximate result based on the data taken from the machine setup in Eurotex Knitwear Ltd. Lastly we can say that iDES dyeing machine consume less space having 100% loading capacity which makes it unique from any other machines in market place.

Data analysis for energy saving

Energy consumption being one of the main concern in a textile industry, a study has been done taking 7 chamber, 1400kg capacity dyeing machine of both iDES and conventional as a sample for a comparison. A clamp meter was used to measure the current flow in the three phase line of the machine keeping same pump speed, same value of the nozzle and equal winch speed in both iDES and conventional dyeing machine to get a precise value. Along with that in both the machine light shade was done to the fabric having a specific GSM.

Energy consumption comparison between Conventional & iDES dyeing machine of 1400 Kg capacity.

study of energy & space consumption between iDES & conventional dyeing machine

clamp meter
Figure 1: Current flow in 1400kg, 7 chamber iDES dyeing machine at its run time taken by clamp meter.
Current flow
Figure 2: Current flow in 1400kg, 7 chamber conventional dyeing machine at its run time taken by clamp meter.

From the above data, we can see that runtime electricity consumption of iDES dyeing machine is lower than Conventional dyeing machine in spite of high GSM fabric in iDES having other parameter same. Power of the machine in its run time is to be determined from its current flow. On the basis of power consumption it can also be said how efficient the machine is compared to the conventional one. Already we can see that the current consumption of iDES dyeing machine is less.

study of energy & space consumption between iDES & conventional dyeing machine

Pump Speed: Same for both iDES and Conventional.

Nozzle opening value: Same for both iDES and Conventional.

Winch Speed: Same for both iDES and Conventional

Maximum Load: 100% in iDES dyeing m/c and 85% in conventional dyeing machine.

Current Flow: More in conventional dyeing machine. In the chart, the red line indicates the curve of conventional dyeing machine and the blue line indicates the curve of conventional dyeing machine.

Upto winch speed both the lines have the same curve where the blue line is lying just underneath the red line. We can clearly see that the maximum load capacity of iDES dyeing machine is greater than conventional dyeing machine and inspite of keeping same value of the parameters pump speed, nozzle and winch speed of both iDES and conventional dyeing machine possessing same capacity (1400kg, 7 chamber) they differs in the consumption of current flow during the run time. This is where the actual positive side of iDES dyeing machine comes out. Current flow in iDES dyeing machine is lower than that of the conventional one and at the same time the production is also more in iDES dyeing machine as the loading capacity is more. So the power consumption is lower in iDES dyeing machine.

Calculation (power Savings)

Formula,

Power (kW) = √3 VI CosƟ where, V= Voltage I= Current V= 390V CosƟ = 0.8 Calculative Comparison: Considering 7 chamber, 1400 kg dyeing machine.

study of energy & space consumption between iDES & conventional dyeing machine

Result

Energy saved per kg of the fabric is = (Energy consumed in per kg fabric of conventional machine – Energy consumed in per kg fabric of iDES machine) = (0.19-0.16) kW = 0.03 kW Let us consider a dyeing floor of machine capacity 30,300 kg or production capacity (30,300*2.5) =75,750kg (on daily basis 2.5 batch production is assumed).

Amount of energy saved per day for 30,300kg machine capacity or 75,750kg production capacity floor is = (0.03×75,750) kW = 2272.5 kW

Monthly saved= (2272.5×30) kW = 68175 kW

Yearly saved= (68175×12) kW = 818100 kW.

study of energy & space consumption between iDES & conventional dyeing machine

So, total energy saved per year is 818100 kW which is a positive feature of iDES Dyeing machine. Energy saving feature of this machine is a sign of sustainable production for any dyeing factory.

Experimental analysis assuming 33.3 ton Machine Capacity Dyeing Floor

A dyeing floor of machine capacity 30,300 Kg or 75,750 Kg production capacity is assumed for both iDES and Conventional dyeing machine setup. For that six number of 25 kg, three number of 200 kg machine, three number of 400 kg machine, three number of 600 kg machine, three number of 800 kg machine, three number of 1400 kg machine and three number of 1600kg machine were selected to setup a floor of approximately 75 ton production capacity for a calculative comparison of space and energy.

Length = 5 + 5.7 + 2 + 5.7 + 2 + 5.7 + 2 + 5.7 + 2 + 5.7 + 2 + 5.7 + 2 + 4.83 + 2 + 4.83 + 2 + 4.83 + 2 + 10.83 + 2 + 10.83 + 2 + 10.83 + 2 + 13.16 + 2 + 13.16 + 2 + 13.16 + 2 + 14.75 + 2 + 14.75 + 2 + 14.75 + 2 + 25.2 + 2 + 25.2 + 2 + 25.2 + 2 + 28.3 + 2 + 28.3 + 2 + 28.3 + 5 = 463.58

Breadth = 5 + 15.7 + 12 + 15.7 + 5 = 53.4

 

Area = (465.38 × 53.4)

= 24851.292 square feet

= 24851.3 square feet

Length = 5 + 6 + 2 + 6 + 2 + 6 + 2 + 6 + 2 + 6 + 2 + 6 + 2 + 10 + 2 + 10 + 2 + 10 + 2 + 13.6 + 2 + 13.6 + 2 + 13.6 + 2 + 17.5 + 2 + 17.5 + 2 + 17.5 + 2 + 21 + 2 + 21 + 2 + 32.25 + 2 + 32.25 + 2 + 32.25 + 2 + 32.25 + 2 + 32.25 + 2 + 36.5 + 2 + 36.5 + 2 + 36.5 + 5 = 484.55

 

Width = 5 + 17 + 12 + 17 + 5 = 56

Area = (484.55 × 56) = 27134.8 square feet

Area saved = (27134.8-24851.3)

= 2283.5 Square feet

So we can see here that the Area saved is (27134.8- 24851.3) = 2283.5 Square feet in iDES dyeing floor. This area can be used for more machine setup which signifies that the iDES dyeing machine is space saving and economically more suitable for the factory.

Calculation (Cost)

Amount of money saved per kg of the fabric is = (2.04-1.66) taka = 0.38 Taka

study of energy & space consumption between iDES & conventional dyeing machine

Amount of money saved per day for 30,300 kg machine capacity or 75,750 kg production capacity floor is = (0.38×75,750) taka = 28,785 taka

Monthly saved = (28785×30) taka = 863550 taka

Yearly saved = (863550×12) taka = 10,362,600 taka.

study of energy & space consumption between iDES & conventional dyeing machine

= One crore Thirty six lac two thousand and six hundred taka

Area saved is 2283.5 square feet where two more 1600 kg and 600 kg dyeing m/c can be set up. So 1600+1600+600+600 = 4400 kg more production can be done in single batch.

In one day, amount of more production = 4400×2.5 = 11000 kg

Monthly, amount of more production = 11000 × 30 = 330000 kg

Yearly, amount of more production = 3960000 kg

We can see in the chart that the amount of area saved is used for more machine set up and by which more production is being done. Yearly the amount of more production stands to 3960000kg of fabric which is a very profitable sign for any dyeing factory.

Figure 3: Al Amin Akas, Textile Engineering, Dr. M A Wazed Miah Textile Engineering College, Rangpur.

Conclusion

In conclusion, it can be said that IDES dyeing machine is space and energy saving which is a very positive sign for the industries of Bangladesh. No plaiter system, less inner surface area, less heat loss, smaller size of J-box, more loading capacity, less current flow in run time and more economically balanced feature of this IDES dyeing machine altogether plays a vital role for the sustainable production cost, less space and lower energy consumption maintaining standard quality of the fabric. This can be the future of dyeing industries in Bangladesh with its immense potential and advanced features.

If anyone has any feedback or input regarding the published news, please contact: info@textiletoday.com.bd

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