SET - Production Processes and 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)
Leading author: CITEVE Date: December 2014
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
5 - Energy efficiency measures ....................................................................................... 21 5.1 - Energy efficiency measures for Yarn Production process ............................................... 23 5.2 - Energy efficiency measures for Fabric Production process ............................................ 26 5.3 - Energy efficiency measures for Finishing process........................................................... 28 5.4 - Cross-cutting energy efficiency measures ...................................................................... 44
6 – Conclusions and Next Steps ....................................................................................... 72 7 - Reference.......................................................................................................................... 73
SET – Production Processes and Efficiency Measures
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.
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SET – Production Processes and Efficiency Measures
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
3
Specific
Finishing
4
Cross cutting
Organizations DITF (DE) / IVGT (DE) / Centexbel (BE) TMTE (HU)/ IVGT (DE) CITEVE (PT) / IVGT (DE)/ Inotex – ATOK (CZ) ENEA (IT)
SET – Production Processes and Efficiency Measures
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.
Energy consumption on (10 3 toe)
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
SET – Production Processes and Efficiency Measures
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.
SET – Production Processes and Efficiency Measures
3 - Textile production processes The textile industry is one of the most complex industrial chains in the manufacturing industry because of the wide variety of textile products, substrates, processes, machinery and components used, and finishing steps undertaken. Different types of fibers, methods of yarn and fabric production, and finishing processes combinations (preparation, printing, dyeing, chemical/mechanical finishing, etc), all interrelate in producing a finished fabric. The combination of processes and process parameters is almost infinite and has a considerable influence on energy efficiency. Before collecting energy efficiency measures it was fundamental to develop a description of the processes to be used on this project, from the huge variety available, to represent the textile industry, taking mainly into account the energy consumption. First, the major textile processes were defined for a first level of classification: • Yarn production1 • Fabric Production • Finishing Within these main processes, two more specific levels of classification of processes used on the textile industry were defined - second level of classification or phase and third level of classification or subphase. This classification was based on ITMA 2015 Index of Products [3], which is recognized and accepted by the textile sector. The following tables represent the classification of textiles processes in the three different levels to be considered in the next steps of this project and the associated hierarchical identification.
Table 2 - Description of processes and equipments for Yarn Production 1
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.
SET – Production Processes and Efficiency Measures
Process (Level 1)
Phase (Level 2)
Subphase (Level 3) Opening for cotton (1.1.1) Cards (1.1.2)
Spinning Preparation for
Drawing machines for cotton (1.1.3)
cotton fibers (1.1)
Lap winders (1.1.4) Combing machines for cotton (1.1.5) Roving frames (1.1.6) Opening lines for raw wool (1.2.1) Raw wool scouring lines (1.2.2) Carbonising lines (1.2.3) Opening for wool (1.2.4) Worsted cards (1.2.5)
Spinning Preparation for wool
Semi-worsted cards (1.2.6)
fibers (1.2)
Woollen cards (1.2.7) Drawing machines for wool (1.2.8) Combing machines for wool (1.2.9) Back washing machines (1.2.10) Finishers (1.2.11)
Yarn production (1)
Roving frames for worsted yarn (1.2.12) Production of man-made
Extruders (1.3.1)
filaments and fibres (1.3)
Winding (1.3.2) Ring-spinning (1.4.1) Compact spinning (1.4.2)
Spinning (1.4)
Rotor spinning (1.4.3) Air-jet spinning (1.4.4) Other Spinning machines (1.4.5)
Winding, reeling and covering (1.5)
Winding machines (1.5.1) Reeling machines (1.5.2) Covering machines (1.5.3) Autoclaves for steaming (1.6.1)
Yarn steaming, setting,
Heat-setting machines (1.6.2)
moistening and coating (1.6)
Moistening machines (1.6.3) Yarn coating machines (1.6.4)
Texturing, bulking and
Texturing machines (1.7.1)
crimping (1.7)
Bulking and crimping machines (1.7.2)
Doubling and twisting (1.8)
Doubling machines (1.8.1) Twisting machines (1.8.2)
SET – Production Processes and Efficiency Measures
Table 3 - Description of processes and equipments for Fabric Production
Process (Level 1)
Phase (Level 2)
Subphase (Level 3) Sectional warping (2.1.1) Beam warping (2.1.2)
Weaving preparation (2.1)
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)
Water jet weaving (2.2.4) Shuttle looms (2.2.5) Circular weaving (2.2.6) Narrow fabrics weaving (2.2.7)
Preparation for knitting (2.3)
Beam warping (2.3.1) Sectional warping (2.3.2) Circular knitting machines (2.4.1) Flat knitting machines (2.4.2)
Knitting (2.4)
Warp knitting machines (2.4.3) Knitting machines for special purposes (2.4.4)
SET – Production Processes and Efficiency Measures
Table 4 - Description of processes and equipments for Finishing
Process (Level 1)
Phase (Level 2)
Pretreatment (3.1)
Dyeing (3.2)
Finishing (3)
Water extraction and drying (3.3)
Finishing machines (3.4)
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)
SET – Production Processes and Efficiency Measures
4 - Energy in the textile industry In general, energy in the textile industry is mostly used in the forms of: electricity, as a common power source for machinery, cooling and temperature control systems, lighting, office equipment, conditioning, etc., and fuels for steam and thermal fluid boilers and direct fired equipments. In the next figure is represented a breakdown of energy consumption by type of energy for
the European Union (28 countries) for textile and leather industries in 2012.
Share of energy consumption by type in Textile and Leather industries (EU28) Waste 0%
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
SET – Production Processes and Efficiency Measures
and Finishing, main variables affecting that consumption and reference values (when available) for the consumption of each subphase.
4.1 - Energy use in yarn production, main factors affecting energy consumption and reference values Electricity is the major type of energy used in spinning plants. As an example, if the spinning plant just produces raw yarn in a cotton spinning system, and does not dye or fix the produced yarn, the fuel may just be used to provide steam for the humidification system in the cold seasons for preheating the fibers before spinning them together [1]. The factors (triggers) which are most affecting the energy consumption for a determined textile process in yarn 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 5 – Triggers and relevant product groups and benchmarks for Yarn Production
Phase (Level 2)
Subphase (Level 3)
Triggers
Opening for cotton (1.1.1) Cards (1.1.2) Spinning
Drawing machines for
Preparation for
cotton (1.1.3)
cotton fibers (1.1) Lap winders (1.1.4)
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
Combing machines for cotton (1.1.5) Roving frames (1.1.6) Opening lines for raw wool (1.2.1) Spinning Preparation for wool fibers (1.2)
Speed of machine Speed of machine, yarn count Speed of machine
Raw wool scouring lines (1.2.2)
Speed of machine
Carbonising lines (1.2.3) Speed of machine, temperature Opening for wool (1.2.4) Speed of machine
high eveness and tension
SET – Production Processes and Efficiency Measures
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
Drawing machines for wool (1.2.8) Combing machines for Spinning
wool (1.2.9)
Preparation for
Back washing machines
wool fibers (1.2)
(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)
Yarn count, twist factor, Speed of machine
High yarn tension and elongation
Yarn count, twist factor, Speed of machine
Smooth yarn surface, fine count
Rotor spinning (1.4.3) Air-jet spinning (1.4.4) Other Spinning machines (1.4.5) Winding machines (1.5.1)
and covering (1.5)
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
Yarn count, twist factor, Speed of machine Yarn count, twist factor, Speed of machine
Smooth yarn surface, Special soft yarn with high hairiness, low tension
Variable, depending on the type of machine Yarn count, Speed of machine
Reeling machines (1.5.2) Yarn count, Speed of machine Covering machines Yarn count, Speed of (1.5.3) machine
Yarn steaming,
Autoclaves for steaming
setting,
(1.6.1)
Speed of machine, type of fibre, temperature
Cotton
SET – Production Processes and Efficiency Measures
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
Speed of machine, type of fibre, temperature
Relevant product groups and benchmarks for relevant triggercombinations Polyester
Speed of machine, type of fibre, temperature Speed of machine, type of fibre, temperature
Yarns for circular knitting
Speed of machine, type of fibre, temperature Speed of machine, type of fibre Yarn count, Speed of machine
Increase of yarn tension, multi-material mix
Yarn count, twist factor, Speed of machine
4.2 - Energy use in fabric production, main factors affecting energy consumption and reference values The weaving sector consumes almost only electricity. This sector is a major consumer of compressed air, particularly when the looms are air jet. The amount of energy consumed by each loom during its weaving operation can be estimated from the motor capacity and weaving speed. Across the different weaving technologies, weft insertion systems consume a large share of the total electricity use of the equipment. Usually, the lighting has a great weight in terms of electricity consumption, because the weaving sections have many lighting fixtures installed [5]. On the other hand, some amount of thermal energy is consumed in sizing, as one of the possible preparatory operations for weaving. The energy consumption is not necessarily high for the knitting process. However, of the main production facilities for this process, knitting machines have also been undergoing a shift towards high speed and large capacity and fine gauge features; the
SET – Production Processes and Efficiency Measures
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
Beam warping (2.1.2) Weaving preparation (2.1)
Draw-warping (2.1.3)
PES/PA filament yarns only
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)
Staple fiber yarns
Indigo warp dyeing lines (2.1.6)
Water jet weaving (2.2.4)
Speed in bpm, width, warp/weft density , shading motion or Jacquard Speed in bpm , width , warp/weft density , shading motion or Jacquard Speed in bpm , width , warp/weft density , shading motion or Jacquard Yarn material which don’t take-up liquid
Shuttle looms (2.2.5)
Tubular fabrics
Rapier weaving (2.2.1)
Projectile weaving (2.2.2) Weaving (2.2) Air jet weaving (2.2.3)
Yarns with a high hairiness, or electrostatic clamping Denim/jeans production only Different yarn counts and appearance (flame yarn)
Even yarn count and same material
High production and even yarn caracteristic Filament yarns, tapes Small quantities or specialized yarns
SET – Production Processes and Efficiency Measures
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
