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First Prize Textiles

ARVIND LIMITED Gandhinagar (Gujarat)

Unit Profile

Arvind Limited is a textile manufacturer and the flagship company of the Lalbhai

Group. Its headquarters is in Naroda, Ahmedabad, and Gujarat, India. It has units

at Santej which manufactures cotton shirting, denim, knits and bottom weights

(Khakis) fabrics. It has also recently ventured into technical textiles when it started

Advanced Materials Division in 2011. It is India's largest denim manufacturer apart

from being world’s fourth-largest producer and exporter of denim.

In 1997, Arvind set up a state-of-the-art shirting, bottom weights and knits facility,

the largest of its kind in India, at Santej. With Arvind’s concern for environment a

most modern effluent treatment facility with zero effluent discharge capability was

also established.

The unit is certified with ISO 14001:2004, ISO 9001:2008 & in process of

implementing OHSAS 18001:2008.

Production Data

The Production of last two year is shown Below;

Year Production in MT

2012 – 2013 28774

2013 – 2014 35159

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Energy Consumption Data

Energy consumption data for last two Years is shown as below:

Years Electrical Energy in

Million kWh

Thermal Energy in Million

kcal

2012-13 210.30 398272

2013-14 211.80 484919

Specific Consumption Data A. Specific Electrical Energy Consumption Data for last two Year is shown as

below

B. Specific Thermal Energy Consumption Data for last two Year is shown as

below

Energy Conservation Measures implemented

Energy Saving Project No. 1: Improvement in Power Factor to 0.99

Power factor has been achieved by Installation Mixed power factor compensation

• Installation of APFC & Fixed capacitor at MCC panel & PCC panel

• Currently Power factor has been maintained by 0.99 from 0.94

• kVA Demand has reduced by maintaining PF to Unity

Energy Saving Project No. 2: Installation of Voltage Stabilizer in Lighting System – 30 KVA

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• Automatic voltage stabilizer has been installed in

lighting feeder capacity of 30 KVA

• Voltage level has reduced to 245 Volts to 210

volts

• Lumens level has been checked & maintained the

same

Annual Saving : Rs. 1, 39,650 per Annum Investment : Rs. 1, 00,000 per Annum Payback Period : 11 Months

Energy Saving Project No. 3: Replacement in 150 W Mercury lamp with 65 W LED lamps • There are total 350 Nos. of Mercury lamps installed

in plants.

• 62 Nos. of street light have been replaced with 65

Watts LEDs Lamps

• Others lamps are replacing with 65 Watts LED in

Phase-Wise

• Advantage of LED in street light

• Energy Saving - 85 watts Per lamps & More Lumens

& cleaner Light

Annual Saving : Rs. 2, 10,000 per Annum

Investment : Rs. 8, 99,000 per Annum Payback : 51 Months

Energy Saving Project No. 4: Replacement in 36 Watts x 2 nos. by 18 Watts x 2 nos. LED lamps

• There are total 3086 Nos. of 36 Watts X 2 Nos.

installed in Classical – 4 Area

• Replaced 36 Watts X 2 Nos. of FTL with 18 Watts X

2 Nos. LED lamps

• Advantage of LED in street light

• Energy Saving - 36 watts Per fittings

• More Lumens & cleaner Light

Annual Saving : Rs. 35, 60,530 per Annum Investment : Rs. 46, 30,000 per Annum Payback : 15 Months

Energy Saving Project No. 5: Installation of Energy efficient Centrifugal Air Compressor • Initially Compressed air was supplied from Common

Compressor House & Screw compressor were run to

cater additional demand.

• Sp. Power Consumption for Screw Compressor =

210 Watts/ CFM

• Install C700 & C1000 Centrifugal compressors of

165 watts /CFM

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Annual Saving : Rs. 8, 37, 00,000 per Annum Investment : Rs. 3, 50, 00,000 per Annum

Payback : 5 Months

Energy Saving Project No. 6: Installation of Pressure Reducing valve for Cleaning Air Application • Cleaning Air has been provided from Main

compressed air network.

• Pressure requirement for cleaning Air application is

not More than 2.5 barg.

• Pressure Reducing valve has been installed &

pressure 2.5 barg has been maintained at cleaning

Air header

• Time of operation has been also fixed for cleaning

Air. i.e. 9 hrs per day.

Annual Saving : Rs. 8, 12,000 per Annum Investment : Rs. 1, 50,000 per Annum Payback : 2 Months

Energy Saving Project No. 7: Replacement of Conventional H Plant with Fog

Type of H plant • Conventional Type of H Plant has been replaced

with Fog type of H Plant.

• Power Consumption Before Modification = 1200

kWh/ day

• Power Consumption After Modification = 600

kWh/day

Annual Saving : Rs. 16, 00,000 per Annum Investment : Rs. 23, 40,000 per Annum Payback : 18 Months

Energy Saving Project No. 8: Installation Loomspahare concentrated

Humidification plant in place of conventional • Installation Loomspahare concentrated

Humidification plant in place of conventional

• Power consumption for Conventional

Humidification = 72.0 kWh/loom/day

• Power Consumption for Loomspahare

Humidification = 54.0 kWh/loom/day

Annual Saving : Rs. 2, 28, 70,000 per Annum Investment : Rs. 1, 12, 00,000 per Annum Payback : 6 Months

305

Second Prize

Textiles

AARTI INTERNATIONAL LIMITED

Ludhiana (Punjab)

Unit Profile

Aarti International Ltd. represents a 100% cotton yarn manufacturing company,

with an installed capacity of 1,75,000 spindles including 43,400 spindles of compact

yarn. With state of art and technology plant located in Punjab, it has become a

global player in the spinning industry with manufacturing facilities of Slub and Core

Spun Lycra Yarn also.

The company was established in the year 1996 with 27000 spindles and slowly and

steadily expanded itself and has emerged as a global player in the spinning industry

with state of Art and Technology plant, with equipment from renowned machinery

suppliers from India, Switzerland and Germany.

INFRASTRUCTURE Aarti International is equipped with the state of Art machines and technology from

the world's top machinery manufacturers to serve the niche segments.

Preparatory Machines

1. Rieter, Trutzschler and LMW blow room lines for best cleaning results

Loptex Optosonic and SPFPU from Trutzschler for full control of contamination

in the opening process. It is the simplest and most effective system to

remove contamination in the spinning preparation line.

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2. Latest generation cards from Rieter and Trutzschler for higher productivities

and quality.

3. Latest generation of Zinser 68-i speed frames.

Ring Frames

1. Rieter Com4 and Suessen compact yarn Technology to produce best compact

yarns for high end weaving/hosiery applications.

2. Established a successful line of Ring Frames LR60 AX and RXi 240 from LMW

and KTTM

Winding

We have modular winding technology from Schlafhorst and Muratec to meet the

global demands of the textile industry.

Doubling Process

State of Art Technology for double yarns by Volkmann and parallel yarn winding by

Precision propeller winders for the best results.

Fancy Yarns

Amsler Slub yarn Technology and Pinters Core spun attachments add special values

to our product line.

Product Profile

Our top priority is providing efficient and reliable services to the customer. We are

aware that in order to continue as successful spinners we have to add genuine value

to the product. Our experienced staff is familiar with the needs of our clients and

well informed about the peculiarities of the yarn markets. We respect the needs of

every client and strive to satisfy them.

1. 100% Combed Cotton Grey Yarn

2. 100% Combed Cotton Compact Grey Yarn

3. Cotton Slub Yarn (Amsler)

4. Core Spun Spandex Yarn

5. Organic Cotton Yarns & OE Blended Yarns (Certifications from GOTS &

Organic Exchange)

6. Single and Double Yarn

All above products in the count range of Ne20 to Ne 40, for hosiery as well as

weaving applications from various cotton mixings. "90% of our yarn is exported to

high quality conscious customers in Hong Kong, China, South Korea, Taiwan,

Bangladesh & European markets. Product finally ends up in various internationally

accepted & well known brands like Tommy Hilfiger, Walmart, Gap, Marcs & Spencer

etc.

Accreditations

Aarti International Limited also has the following certificates and licenses:

WERNER INTERNATIONAL a management consultant specialized exclusively in the

fiber, textile and fashion industry globally since 1939 has stated that

"Globally, Aarti International Ltd is among the best managed and efficient cotton

spinning plant today, anywhere in the world."

• CERTIFICATE OF MERIT, Second Position Award from PEDA, Punjab (2009-10)

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• USTERIZED quality certificate from USTER, Switzerland

• OEKO TEX Certificate from HOHENSTEIN, Germany

• CU Certification GOTS

• CU-Certification-OE

Best Engineering Practices

1. Daily power & losses monitoring for analyzing any deviation and timely

corrective action.

2. Energy conservation teams at various levels

a). Shop floor level workers

b). Officers & Managers

c). Head of Departments & Top Management

3. Regular suggestions are welcomed from all the workers and staff for

improvements and savings.

4. Cross functional teams of Production, Maintenance & Engineering are

regularly working for continuous improvement.

5. Regular use of Temperature / ultrasonic guns for monitoring machine health

and panel temperatures.

6. Compressed air consumption is monitored by thermal mass flow meters and

one team of maintenance; engineering is regularly working for detecting and

attending leakages.

7. Similarly regular monitoring of water pumped and consumed is monitored in

utility and workers colony.

8. Water and power saving training programs are organized for workmen.

9. For cost optimization regular thrust is given for local development of costly

OEM parts.

Health Safety and Environmental Policy

Aarti International Ltd., believe that Safety and Health of our employees and Safe

Working Environment are fundamental to our operations. We will ensure this and

continue our commitment to safety, health and environment by:

• Complying with relevant legal statutes.

• Using and maintaining Personal Protective Equipments, Systems and facilities

to provide a safe work environment.

• Conservation of resources and preventing pollution

• Creating awareness regarding safety, health and environment through

training sessions and internal communication.

• Continually improving safety, health and environment aspects through

objectives, targets and management programs.

• Continually improving environment performance of our processes & products

and ensure prevention of pollution at every stage.

• Strictly complying with the applicable environment legislation & standards.

• Ensuring effective use of resources in the areas of energy, fuels oils, water

etc.

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• Water treatment (de-scaling) to be carried out at regular intervals. Water

treatment is carried out at regular intervals

• To carry planned plantation and maintenance of gardens within the premise

of the company. The company boasts of being the first in its kind to have

planned plantations and gardens , giving workplace an amiable atmosphere

and contributing to the environment whilst ensuring a sustained ecological

balance

• Encouraging the usage of environment friendly technologies to aid elimination

of the hazardous materials.

• Promoting the cause of environmental protection and preservation amongst

employees and other parties by inculcating sensitivity to the environmental

concerns.

Process Flow Chart

MAJOR ENERGY CONSERVATION PROJECTS (YEAR 2013-14)

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Certificate of Merit

Textiles

MARAL OVRSEAS LIMITED - SAROVAR PLANT

Khargone (Madhya Pradesh)

Unit Profile

Maral Overseas Ltd is one of India’s largest vertically integrated textile companies.

This export led company is a part of the $ 1114 million LNJ Bhilwara Group, whose

leadership in textile business is complemented by high technology sectors of

graphite electrodes and power generation.

Set up in 1991 at Maral Sarovar, it is a $ 139 million (834 crore rupees) composite

company. Maral has earned reputation of an extremely reliable supplier in the global

market having modern manufacturing technology, quality systems and quality

relationships.

The Energy Conservation is a top priority at MARAL OVERSEAS LTD (MOL). In view

of scarce energy resources in the competitive world market, green house, gas

emission etc., the commitment of the Company towards energy conservation is one

of the important aspects. All efforts are made to find out most energy efficient

equipments and replace them with the non efficient or less efficient working

equipments every time. Consistent efforts in R&D and technology in innovation are

also made to reduce the wastage level in order to become energy efficient Company.

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Power & Specific Power Consumption

Single Yarn

Double Yarn

Knitted Fabric

Dyed Yarn

Power Consumption -Single Yarn

530.50

531.00

531.50

532.00

532.50

533.00

533.50

2012-13 2013-14

Specific Power Consumption - Single Yarn

2860

2870

2880

2890

2900

2910

2920

2012-13 2013-14

Power Consumption - Double Yarn

27.80

27.82

27.84

27.86

27.88

27.90

27.92

27.94

27.96

2012-13 2013-14

Specific Power Consumption - Double Yarn

1180

1190

1200

1210

1220

1230

1240

1250

2012-13 2013-14

Power Consumption - Knitted fabric

11.75

11.80

11.85

11.90

11.95

12.00

12.05

12.10

2012-13 2013-14

Specific Power Consumption - Knitted fabric

328

328

329

329

330

330

331

331

332

2012-13 2013-14

Power Consumption - Dyed Yarn

23.00

23.50

24.00

24.50

25.00

25.50

26.00

26.50

2012-13 2013-14

Specific Power Consumption - Dyed Yarn

1890

1900

1910

1920

1930

1940

1950

1960

2012-13 2013-14

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Dyed Fabric

Thermal & Specific Thermal Energy Consumption

Single Yarn

Dyed Yarn

Dyed Fabric

Power Consumption - Dyed Fabric

49.00

50.00

51.00

52.00

53.00

54.00

55.00

56.00

57.00

58.00

59.00

2012-13 2013-14

Specific Power Consumption - Dyed Fabric

1230

1240

1250

1260

1270

1280

1290

2012-13 2013-14

Thermal Energy Consumption - Single Yarn

645

650

655

660

665

670

675

680

2012-13 2013-14

Specific Thermal Energy Consumption - Single Yarn

0.035

0.036

0.036

0.037

0.037

0.038

2012-13 2013-14

Thermal Energy Consumption - Dyed Yarn

5300

5400

5500

5600

5700

5800

5900

6000

6100

6200

2012-13 2013-14

Specific Thermal Energy Consumption - Dyed Yarn

0.00

1.00

2.00

3.00

4.00

5.00

6.00

2012-13 2013-14

Thermal Energy Consumption - Dyed Fabric

38500

39000

39500

40000

40500

41000

41500

42000

2012-13 2013-14

Specific Thermal Energy Consumption - Dyed Fabric

7.50

8.00

8.50

9.00

9.50

10.00

10.50

2012-13 2013-14

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Major Projects implemented for Energy Conservation at Maral

Overseas Ltd during the year 2013-14

ELECTRICAL

1. Replacement of Auto coner

In spinning unit there were six Auto coner of Schlafhorst make 238-146 model.

These machines were replaced with new generation Muratec energy efficient Auto

coner machines.

Measure Annual electrical saving : Rs.17.25 Lacs Investment : Rs. 1010 Lacs

2. Replacement of Comber

In spinning unit there were sixteen number of low production Rieter comber (Model

E 7/5) machines. These machines were replaced with eight numbers new generation

high production energy efficient Rieter Comber (Model E 80) machines.

Measure

Annual electrical saving : Rs. 12.96 Lacs Investment : Rs. 506 Lacs

3. Replacement of Unilap

In spinning unit two numbers of inefficient & low production Rieter Unilap (Model E

3/5) machines were replaced with new generation high production energy efficient

Rieter Omega lap (Model E35) machine.

Measure Annual electrical saving : Rs. 2.05 Lacs Investment : Rs. 159 Lacs

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4. Replacement of Finisher Draw frame

In spinning unit twelve numbers of inefficient, low production & quality Rieter Draw

frame machine (Model RSB 851) machines were replaced with nine numbers new

generation high productive & quality energy efficient Rieter Draw frame (Model D45)

machines.

Measure Annual electrical saving : Rs. 6.34 Lacs Investment : Rs. 260 Lacs

5. Replacement of Air Conditioner

Unit has replaced old ten number of inefficient air conditioner with star rated air

conditioners.

Measure

Annual electrical saving : Rs. 1.28 Lacs Investment : Rs. 4.3 Lacs

6. Replacement of LED Tube rod

In department Unit has replaced the conventional 2500 tube rod and electronic

choke with LED tube rod. Thus save the energy of 16 W with each replacement.

Measure Annual electrical saving : Rs. 21.43 Lacs

Investment : Rs. 28.75 Lacs

7. Replacement of Pumps

Total ten number of monoblock pumps replaced with energy efficient pumps to save

the energy.

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Measure Annual electrical saving : Rs. 3.5 Lacs Investment : Rs. 9.6 Lacs

8. Modification in compressed air line

In process area for cleaning of machine compressed air being used. This connection

taken from the machine compressed air line of high pressure. Unit has laid down

separate compressed air line for cleaning of machine at low pressure.

THERMAL

9. Reduction in process cycle time in yarn dyeing

Modification in yarn dyeing machine by installation of dynamic rinsing system to

reduce the process cycle time. The above modification carried out in 6 nos

machines.

Measure Annual electrical saving : Rs. 4.46 Lacs Annual thermal saving : Rs. 10.4 Lacs

Investment : Rs. 5.5 Lacs

10. Recovery of heat from flash steam

Recovery of heat carried out by using the flash steam of trap of Santax Progress

dryer machine of process house. The recovered heat used to increase the

temperature of boiler feed water.

Measure Annual thermal saving: Rs. 5.5 Lacs Investment : Rs. 1.2 Lacs

11. Recovery Hot water

Heat recovery by recycling m/c cooling water for process in dyeing machines.

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Measure Annual thermal saving : Rs. 20.6 Lacs Investment : Rs. 20.5 Lacs

12. Reduction in process cycle time in Fabric dyeing machines by process

improvement

Project (PIP) undertaken with M/s Huntsman, USA to Optimize the process

(Scouring, pre-treatment aquacron and soaping process) and reduced process cycle

time in fabric dyeing.

Measure Annual electrical saving : Rs. 8.93 Lacs

Annual thermal saving : Rs. 38.88 Lacs Investment : NIL

13. Reduction in Re-dyeing in Fabric dyeing machines by process improvement

Project (PIP) undertaken with M/s Huntsman, USA and improved process robustness

and reduced re-dyeing in fabric dyeing.

Measure Annual thermal saving : Rs. 26.5 Lacs Investment : NIL