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Compressed Air is a key utility in the Textile industry. It is required at nearly every stage of the manufacturing process across industries, fabrics and processes. Most Textile companies rely on reliable, clean Class 0 Oil-Free air for these processes, but many do not understand how to optimize their usage of this air to substantially reduce their energy costs. Compressors are needed for precise control of pneumatic valves and cylinders, jet looms, spinning frames, sewing machines and blow guns to produce the garments that the world wears.

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Processes such as power looms, process house & ginning mills, denim spinning, polyester filament yarn (PFY), texturing units and integrated cotton textiles require a varying degree of compressed air, anywhere from 30 cfm to 40,000 cfm. Ingersoll Rand’s range of compressed air solutions, including oil-free rotary screw or centrifugal technologies, for oil-free market applications has a reputation for being highly reliable and efficiently designed. 

Besides compressors, Ingersoll Rand also offers the widest range of technologies for Air Treatment and Filtration solutions. Selecting the right air treatment helps to increase the working life of production equipment, providing consistent product quality, meeting ISO standards and legal requirements, lower service costs, energy savings and ultimately customer satisfaction. Our highly-trained Service Technicians can perform audit solutions for your plant and compressed air system to deliver a unique combination for efficiency, reliability and operation that only Ingersoll Rand can provide.


HOW TO OPTIMIZE A COMPRESSED AIR SYSTEM

The most common areas to save energy and operating costs for compressed air systems in the Textile industry are:


  • Evaluating current air compressors to determine if an overhaul, upgrade or replacement can realize gains or savings in production.
  • Evaluation of the performance of air treatment requirements such as Dryers, Filters & FR units installed near points of use in the compressed air system. Undiagnosed air treatment issues can cause quality issues in production processes.
  • Evaluation of pressure requirements from different processes and (if required) segregation of low & high-pressure processes.
  • Determining System Pressure Optimization for various work processes to maximize energy consumption.
  • Reviewing the usage waste heat from the compressors into a heat recovery system for use in boiler make-up or hot water applications.
  • Reviewing the distribution and storage of compressed air throughout the system to reduce pressure drop.
  • Optimization for air consumption and pressure for cleaning air applications (one of the largest wastes of compressed air in the Textile industry)
  • Establishing effective controls on the operation of the compressed air equipment to optimize and sequencing.
  • Creating effective leakage management programs and designated teams to manage them.

SIX STEPS TO OPTIMIZE YOUR AIR SYSTEM

SixWaysToOptimizeAirSytem
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