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:
Compressed air is a key utility in the Textile industry, both the segments of Natural & Man-made textiles. Compressed air is more or less required at every stage of manufacturing particularly large volume of air is required for integrated cotton textile industries having Airjet Looms & as well in the Polyester yarn industries. Compressed air is a very critical requirement in the PFY valued added segment such as Texturing.
Most textile companies rely on compressed air in their production, and improving the usage of compressed air will have significant economic benefit to the textile industry.
Choice of compressed air for different applications
Air requirement in the textile industry can be segregated under ♦ Low ♦ Medium ♦ Large volume consumers. Typically power looms, process house & ginning mills required low air between 30-500 cfm. Denim spinning, medium PFY industries require medium air between 500-1,500 cfm. Large polyester yarn integrated plants, texturing units & integrated cotton textiles may require anywhere between 2,000-40,000 cfm.
Ingersoll Rand’s range of air compressors for oil free market applications has a reputation for being highly reliable and efficient supplier of oil free air. Time proven 2-stage air-end compression module of rotary screw compressors features precision machined rotors and gearing, advanced ultra coat rotor protection, anti-friction bearings, stainless steel air seals and a unique labyrinth oil seal design – all ensuring years of reliability, trouble free operation.
Air quality is one of the major concerns & high quality air requirement is essential in integrated textile units. However, the preparatory segments such as ginning mills, spinning mills & process units can use lubricated compressors with well-designed air filtration system.
The possible saving opportunities in the textile industries are:
- Migration to new technology air compressors in old installations / plants, for example considering 2-stage rotary or 3-stage centrifugal compressors instead of existing old reciprocating or single-stage screw compressors
- Proper evaluation on the performance of air treatment requirement such as dryers, filters & FR units installed near points-of-use
- Properly evaluating pressure requirement of different processes and if required segregation of low & high-pressure consumers
- System pressure optimization for unregulated consumers
- Evaluating usage of waste heat from compressors (use of waste heat recovery systems for use in boiler make-up or hot water application)
- Re-look at distribution & storage to minimize the pressure drops
- Optimize air consumption & pressure for cleaning air application (this is one of the largest wastage in most of the textile industries)
- Have effective controls on the operation of the compressors for better optimization & sequencing
- Effective leakage management program & designated team for the same
Centrifugal compressor technology has been limited to mostly process applications due to initial cost. It is the preferred method of compression when the highest reliability and absolute best air quality is required. Ingersoll Rand was the first to pioneer a fully packaged integrally geared design Centrifugal compressor, and today manages an extensive portfolio of offerings.
Besides Compressors, Ingersoll Rand offers the widest range and technologies for Air Treatment and Filtration solutions. Selecting right air treatment product helps you in increase the working life of production equipment, providing consistent product quality, meeting ISO standards and legal requirements, lower service costs, energy saving and ultimately customer satisfaction. The Plant Audit Solution services deliver a unique combination for overall optimized efficiency, reliability and operations.
Six Steps to Optimize your Air System:
- Design - Critical requirements mapping; Application engineering; System design; Lifecycle cost planning; System assessment options
- Supply - World-Class compressor efficiency; Air treatment for aptimized air quality; Performance enhancing components
- Install - Effective project management; Total turnkey solutions; Problem-free commissioning; Complaint condensate management
- Operate - Advanced system controls; System health monitoring; Remote connectivity; Capital conscious pay-per-use air; Rental solutions
- Maintain - Comprehensive service programs; Genuine replacement parts; Global technical support; 24/7 service availability; Service technology; System assessment options
- Extend or Renew - Remanufactured equipment; System net profits; airend exchange programs; Performance & reliability upgrades
Contact Us for more information on Ingersoll Rand's solutions for textiles industry.