This issue of SITRA NEWS covers the following topics:

Page no.

PRODUCTIVITY AND COSTS Quality Assurance in spinning mills a case study TECHNICAL NOTES Influence of yarn friction on knittability of cotton yarns PROJECTS Inter-relationships between Deviation Rate in yarn mass (DR%) and variations in yarn tensile characteristics MEDICAL TEXTILES - Series 19 CONSULTANCY SERVICES OFFERED BY SITRA DURING JANUARY FEBRUARY 2013 STAFF NEWS TRAINING PROGRAMMES ABSTRACT OF A TECHNICAL ARTICLE 1

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Quality Assurance in spinning mills a case study

Quality control is the watchword in the competitive industry like textiles as it affects the user need as well as profitability. It (QC) is generally a procedure or set of procedures intended to ensure that a manufactured product or a performed service adheres to a defined set of quality criteria or meets the requirements of the client or customer. Though all spinning mills are having a quality control department, nevertheless, in most cases, the activities of QC need to be enhanced with a systematic approach in meeting the quality requirements of a product. This process is known as Quality Assurance (QA). QA is the systematic measurement in comparison with a standard, monitoring of processes and an associated feedback loop that confers error prevention. Two principles are included in QA: Fit for purpose, the product should be suitable for the intended purpose and Right first time, mistakes should be eliminated. Of late, the importance of QA has been picking-up in spinning mills. Many mills, more particularly those are largely in export which business / having a group of mills, have a QA department in the place of QC department. To highlight the activities of QA in spinning mills, a typical example is given in this note as case study. Quality Assurance in a spinning mill a case study The activities/functions of Quality Assurance department of a textile mill, having its spinning units working in different places, are given below:
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Organisation structure All the units are having their own testing laboratories with a range of testing equipment like Uster HVI Spectrum, Uster AFIS Pro2, computerised count balance, Uster Tester 5, Uster Tensorapid 3, Uster Tensojet 4, Uster Zweigle Hairiness tester, etc. Each unit has a Quality Assurance manager with required supporting staff including lab assistants. The QA managers of individual units report to the QA manager of the Central Office. Activities/functions of individual units QA department - Testing of raw material, inter-mediate products and final products. - Conducting various process control studies - Ensuring that testing instruments are calibrated as per schedules. - Analysing customer complaints and replying to the customers within a specified time. - Acting or assisting as management representative for the implementation of Quality Management System ISO 9001, Environmental Management System (ISO 14001), Occupational Health and Safety Management System (OHSAS 18001), etc. - Analysing causes for abnormality, etc. Central QA department Some of the unique features of the Central QA department are mentioned below: 1. All the test results from the individual units are directly uploaded to QA server from the testing instruments. Once the authorized person in the respective units approves the test results, the same can be monitored by the Central QA department. This helps to check/compare the quality parameters of the different units.
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2. Customer complaints are also uploaded in a separate system, provided for effective handling of customer feedback. If a reply has not been sent to the customer within a prescribed time, a reminder message will be sent to all the persons concerned (Marketing/Production/QA) by marking a copy to the top management. 3. Based on the requirement of QA/marketing department, the software and servers for handling test results and customer feedback are created, maintained and updated by the mills own EDP team. The following are the main activities of the Central QA department other than the routine schedules. 1. To review periodically the testing schedules, activities and procedures between units for standardisation. 2. To co-ordinate with marketing department while finalising the order regarding technical specifications. 3. To prepare standards for all in-process testing with control and alarming limits, which are reviewed periodically and revised whenever necessary. 4. To prepare quality standards for end product and get approval from the top management. 5. To conduct round test between the units at regular intervals for ensuring the correct working of various testing equipment. 6. To share information regarding the trials conducted in the respective units with the other units. 7. To assist in developing new products. 8. To co-ordinate with other departments such as Production, Engineering, Maintenance, Human Resource, etc., and organise management review meeting, group technical meeting, etc. 9. To organise internal and external audits for implementation of systems such as ISO 9001, ISO 14001, OHSAS 18001, etc.

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Customer feedbacks handling procedure The mill has fixed a time frame for addressing the customer feedback. The units concerned should send the feedback to the marketing department with a detailed analysis report within 96 hours. In general, the feedback should be addressed to the customer within a span of 7 days. Otherwise, a reminder message will be forwarded to all the persons concerned (Marketing/Production/QA) by marking a copy to the top management. The following flowchart explains about the procedure of handling the customer feedback.

Feedback from customer to marketing department

Immediate acknowledgement by the marketing department to the customer

Forwarding the customer message/samples to QAD of the respective units

Circulate the complaint to all the concerned persons in the unit by the QA manager Based on the customer priority, nature of complaint, etc. make a visit to the customer

Aanalyse the feedback based on standard procedure/checkpoints

A
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A Suitable reply will be sent to the customer by the marketing department Detailed reply should be forwarded to the marketing department by the respective units QA department

Review the various feedbacks in the periodical meetings at Central Office

Monitor the effectiveness of preventive action in the subsequent lots

Flowchart Addressing customer complaints - Liaison and Consultation division

Influence of yarn friction on knittability of cotton yarns

Yarn friction contributes to difficulties during knitting in two ways firstly, it affects the tension of the yarn supplied to the knitting elements and secondly, a high friction may increase the abrasion of yarn with knitting elements and guides. Tension in knitting is one of the factors controlling the amount of yarn placed round the needles (length of yarn per stitch) and therefore, it affects the length of knitted goods. The final tension under which the yarn is laid round the needles depends on the take-off tension from the package and the friction at all points of contact of the yarn i.e., guides, tensioning devices, needles, etc.

SITRA News

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As per studies conducted at SITRA and elsewhere, the increase in yarn tension is significantly influenced by the co-efficient of dynamic friction () of yarn with metal surfaces. The increase in tension for various yarn values after passing over guides are given in Table 1. Table 1 Increase in tension for various values after passing over different number of guides
0.15 0.25 0.35 0.65 0.90 Factor by which tension increases 1 guide 2 guides 3 guides 4 guides 1.3 1.6 2.0 2.6 1.5 2.2 3.2 4.8 1.0 3.0 5.2 9.1 2.8 7.7 21.0 59.0 >4.0 >17.0 >69.0 >286.0

It is important that the co-efficient of friction should be low and uniform. A sudden increase in take-off tension may produce a break in the yarn, and a press off will be the result. Also, small changes of tension for a short duration may produce differences in loop length. As per available literature, the variations in the length of yarn in the loop and the total length of knitted goods are often due to the differences in yarn tension, which depends on the friction between the yarn and objects with which the yarn comes into contact. The results of a study conducted at SITRA in this connection are shown in Figure 1.

Figure 1 Relationship between yarn tension and yarn length per 1000 stitches
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In order to reduce the excessive tension generated during knitting, the co-efficient of dynamic friction () requires to be maintained between 0.15 to 0.17. Hence, waxing during cone winding is popular for knitting yarns. For better performance, the wax pick-up during winding may be maintained in the region of 0.15% so that can be maintained within the required limits. - Dr.K.P.Chellamani, Spinning division

Inter-relationships between Deviation Rate in yarn mass (DR%) and variations in yarn tensile characteristics.
An uneven yarn gives rise to a patchy fabric. Very high levels of unevenness also results in loss of yarn strength. In the recent past, a new parameter called Deviation Rate (DR %) is introduced as a quality criterion in yarns to be measured and monitored. DR is defined as the ratio of the length of yarn, which has mass exceeding pre-set mass limit to a given cut length of yarn. DR is a sort of medium term variation in spun yarns. Earlier SITRA had conducted some studies on the effect of fibre properties and process variables on deviation rate in yarn mass. Studies pertaining to the influence of yarn mass variation on tensile property variations are scanty in literature. Hence, SITRA has conducted a study to evaluate the extent of relationship between deviation rate (DR %) and variations in yarn tensile characteristics. Single yarn strength CV %, single yarn elongation CV % and weak spots in the yarn were taken as the parameters that broadly represent the tensile property variations in the spun yarn, in the study.

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Materials and methods 51 yarn samples differing widely in their deviation rate values (DR%) in the count range of 20s to 100s were collected from the member mills. These samples were tested for single yarn strength CV %, single yarn elongation CV % and the number of weak spots in a given length of yarn. In the present study, weak spot has been defined as Spots in the yarn with breaking strength value lower than 70 % of the average breaking strength of the yarn. To assess the presence of weak spots, 5000 m of yarn has been taken as the sample length. Since weak spot is a rare occurrence, testing a longer length of yarn is essential to arrive at a realistic estimate. An expression connecting deviation rate in yarn mass with yarn strength CV %, elongation CV % and weak spots in yarn has been developed. Prediction expression connecting deviation rate in yarn mass and variations in tensile characteristics. Theoretically, one would expect a good association between variation in yarn mass and variations in tensile characteristics. The following linear expression has been arrived at in this connection. DR% = (3.5 x strength CV %) (1.8 x elongation CV %) (0.1 x No. of weak spots / 5000 m) + 10 .. (i) The strength CV %, elongation CV % and weak spots in the yarn were measured using Tensojet tensile testing instrument. The advantage of using Tensojet instrument is that it directly provides information on the extent of weak spots in the yarn. Moreover, testing speed in the Tensojet is high at 400 m/ min which facilitates testing of longer lengths of yarn in a relatively shorter period of time. The predicted values give a very close fit with actual deviation rate resulting in a high correlation of 0.91 (Figure 1).
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Averageerrorofestimate=1DR%

Figure 1 Relationship between actual DR% and predicted DR% For the benefit of the mills who do not have the Tensojet equipment, the yarn quality attributes were also evaluated using Tensorapid instrument and a prediction expression has been derived at. DR% = (3.3 x strength CV %) (2 x elongation CV %) (0.1 x No. of weak spots / 5000 m) + 19 .. (ii) The values predicted from the above expression also showed a good correlation of 0.89 with the error of estimate at 2 DR %. Effect of cone winding on DR % In view of the fact that majority of the mills are using automatic cone winding with stringent clearing of their yarns, it is of interest to know what happens to the deviation rate in the ring yarns after cone winding. Hence, the ring yarns and the corresponding cone yarns, collected from the member mills, were tested for the deviation rate and the values are given in Table 1.

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Table 1 Deviation rate in cop yarns and the corresponding cone yarns
Deviation rate (DR %) S. No. 1 2 3 4 5 6 Yarn count 20 K 30 C 40s C 60 C 80 C 100s C
s s s s

Ring yarn (A) 30.40 22.67 22.92 20.70 21.67

Cone yarn (B) 28.80 21.56 25.25 21.62 18.90 20.00

Difference (A B) (absolute values) 1.60 1.11 1.25 1.30 1.80 1.67

Due to cone winding, the deviation rate in the yarn mass generally comes down which is attributed to the removal of objectionable yarn faults in winding. The extent of reduction in the deviation rate after the cone winding, on an average, is around 1.5 DR% (absolute values). The difference in the quantum of reduction in DR % between counts may be due to the differences in fault clearer settings maintained by the mills for different counts. - K.P.Chellamani, D.Veerasubramanian & M.K.Vittopa, Spinning division

MEDICAL TEXTILES
Series 19

Wound dressings and their application areas

The major properties of some wound dressings in the market and their application areas are given in Table 1. Table 1 Types of wound dressings and their application area0s
Wound dressing type Gauze Application areas & other relevant particulars Dressings can stick to the wound surface and disturb the wound bed when removed Use d for minor wounds or as secondary dressings

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Table 1 (contd..)
Wound dressing type Tulle Semi permeable film Application areas & other relevant particulars Dressing does not stick to wound surface Suitable for flat, shallow wound and for patients with sensitive skin Sterile sheet of polyurethane coated with acrylic adhesive Transparent allowing wound checks Suitable for shallow wound with low exudates Composed of carboxymethyl cellulose, gelatin, pectin, elastomers and adhesives that turn into a gel when exudates are absorbed. This creates a warm, moist environment that promotes debridement and faster healing Can be used in wounds with light to heavy exudates, sloughing or granulating wounds Available as adhesive or non-adhesive pad, paste powder and self - adhesive pads Composed mainly of water in a complex network of fibres that keep the polymer gel intact. Water is released to keep the wound moist Used for necrotic or sloughy wound beds Composed of calcium alginate (a seaweed component). When in contact with wound, calcium in the dressing is exchanged with sodium from wound fluid and this turns dressing into a gel that maintains a moist wound environment. Used for exudating wounds, debridement of sloughing wounds, low exudating wounds etc. Designed to absorb large amounts of exudates Dressings come in pads, gels or particles Promote the deposit of newly formed collagen in the wound bed. Absorb exudates and provide a moist environment Absorb large volume of exudates from discharging wounds Help to reduce the frequency of dressing changes. Reduced adherence to a drying wound Can be removed without causing trauma to the wound and surrounding skin Dressing coated with soft silicone as an adhesive or a wound contact layer Suitable for almost all indications where it is important to prevent trauma to the wound and the surrounding skin Combine the properties of hydrocolloids and polyurethane foams, making the dressing easy to apply and remove and last longer than any of these products used alone.

Hydrocolloids

Hydrogels Alginates Polyurethane or silicone foams Collagens Foams Atraumatic dressings Soft silicone dressings Composite wound dressings

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Different types of wounds and the different stages of healing the wound require different dressings or combinations of dressings. Table 2 shows suitable dressings for different wound types. Table 2 Suitable dressings for different wound types
Wound type Clean, medium-to-high exudates (epithelialising) Clean, dry, low exudates (epithelialising) Clean, exudating (granulating) Slough-covered Dry, necrotic Dressing type Paraffin gauze Knitted primary dressing P erforated plastic film-faced dressing Vapour -permeable adhesive film dressing Hydrocolloids Foams Alginates Hydrocolloids Hydrogels Hydrocolloids Hydrogels

To be continued - K.P.Chellamani and M.K.Vittopa, Spinning division

Consultancy services offered by SITRA during January - February 2013 MEDICAL TEXTILES - 11
S.no. 1. 2. 3. Type of study No. of mills 1 1 2 Techno-economic viability study Powerloom machinery inspection for district industries centre Energy audit

Besides the above major consultancy studies, SITRA also offered solutions to four adhoc problems in the area of spinning process. Thirty nine instruments were calibrated, 1 instrument was certified and 232 accessory samples were tested.

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Meetings attended
Dr. Prakash Vasudevan, Director, attended the following meetings, the appraisal & review of Technology Mission on Technical Textiles (TMTT) by M/s.Investment information Credit Rating Agency (ICRA) Management consulting services, held at Office of the Textile Commissioner, Mumbai, on 4th January 2013. the BIS meeting, held at BIS Manak Bhavan, New Delhi, on 16th January 2013. the meeting of the Standing Council for Market Access Agreement (SCMAA) under the Chairmanship of Shri V.Srinivas, Joint Secretary (Exports), held at Udyog Bhavan, New Delhi, on 17th January 2013. the 6th meeting of Project Monitoring & Approval Committee (PAMC) under Research & Development Scheme of Ministry of Textiles, held at Office of the Textile Commissioner, Mumbai, on 28th January 2013. the 4th meeting of Project Monitoring & Approval Committee (PAMC) to consider R & D projects, held at Udyog Bhavan, New Delhi, on 26th February 2013.

Dr. K.P.Chellamani, General Manager - Projects, attended the 18th purchase committee meeting of COE-Indutech held at PSG College of Technology, Coimbatore on 22nd February 2013. Dr. K.Sajjan Rao, Research Associate & Head of Training division attended the meeting of the empowered Committee on Integrated Skill Development Scheme (ISDS) held under the chairmanship of Secretary (Textiles) to take stock of the progress made by Implementing Agencies
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(IAs) under component - I of the scheme.

Papers published
1. K.P.Chellamani and R.S.Vignesh Balaji Medical textiles using nonwoven Technology, SITRA E-Bulletin, January 2013, 1 (1). 2. J.Sreenivasan, P.Subash and D.Shanmuganandam No load power measurement in motors in spinning mills - case studies, Asian Textile Journal, February 2013, 22 (2). 3. D.Shanmuganandam, P.Subash and J.Sreenivasan Towards zero burnouts in motors in spinning mills, The Indian Textile Journal, February 2013, CXXIII (5).

Papers presented / Lectures given

List of papers presented at 54th Joint Technological Conference held at Ahmedabad Textile Research Association, Ahmedabad on 9th January 2013: 1. Study of failure in electronic circuits of textile machine controls and instruments - S.Sugumar, G.Chandrasekaran. 2. Interrelationships between deviation rate in yarn mass (DR%) and other tensile characteristics & fabric appearance - K.P.Chellamani, M.K.Vittopa & D.Veerasubramanian. 3. Towards zero burnouts in motors in spinning mills D.Shanmuganandam, P.Subash & J.Sreenivasan Dr. K.P.Chellamani, General Manager - Projects, delivered the following lectures: Emerging trends in textile industry for the senior staff of M/s. Super Spinning group of mills, Hindupur on 29th January, 2013. Application possibilities of nano technology & plasma technology in textiles for the senior staff of M/s. Super Spinning Mills,
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Coimbatore on 12th February, 2013. Mr. Sakthivel Perumalsamy, Head - Centre of Excellence for Medical Textiles, delivered the following lectures: Medical textiles - promising past and prosperous future, at Indian Medical Devices Industry (IMDI) conference held at Ahmedabad on 9th January, 2013. Medical textile standards at IMDI conference held at Ahmedabad on 10th January, 2013. Medical textiles - an investment proposition, at Rotary Clubs of Coimbatore East & Downtown on 19th February, 2013.

Visits
Dr. Prakash Vasudevan, Director, visited the Technotex 2013, held at International Trade Promotion Organisation (ITPO), Pragati Maidan, New Delhi, on 17th January 2013. Mr. K.Balasubramaniyan, Assistant Director, made visits to the following places: - Naval Science and Technology Laboratory (NSTL), Visakapattinam, Andhra Pradesh - DRDO Lab, for the development of a new winding technology for winding 0.60 mm mono optical fibre cable. - Sidd Life Sciences, Chennai for the development of a new weaving machine for weaving hallow fibre matt for membrane oxygenator. - DIMA products, Vapi, Gujarat State to observe the functioning of the sanitory napkin manufacturing machinery for CoE - Meditech. Mr. Sakthivel Perumalsamy, Head - Centre of Excellence for Medical Textiles, visited the Vibrant Gujarat Expo, held at Ahmedabad on 8th January, 2013.
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TRAINING

HOK

Seminar on Energy Conservation in Industries SITRA organised a seminar on Energy Conservation in Industries on 7th February 2013 at SITRA premises. A total of 190 participants from textile mills and other industries attended the programme. In-house Supervisory Development Programme At the request of a member mill, SITRA conducted an in-house supervisory development programme during January 29 - 31, 2013. The programme covered technical topics like labour and machine productivity, yarn realisation and waste control, quality management in spinning, process control in spinning, energy conservation, TQM and maintenance practices to be followed and right work methods for operatives. The programme was well received by the participants, totalling 22. Pre-employment training and retraining programmes for textile workers One out-station mill availed SITRAs training services for their workers. In all, 20 opertives were trained in 2 batches for the tenting jobs in ring spinning and auto cone winding. The training programmes were conducted in Kannada. INTEGRATED SKILL DEVELOPMENT SCHEME (SITRA ISDS) The Integrated Skill Development Scheme initiated by the Ministry of Textiles, Govt. of India, aims to leverage the strength of institutions like SITRA to augment the skill resources of the industry for enhancing capabilities for skill development. Under this scheme, SITRA is offering 13 different skill development programmes. Following are the details of the programmes that were conducted during Jan. - Feb. 2013.
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Seventeen outstation and seven local mills availed for training their operatives. Totally, 586 operatives were trained in 29 batches in spinning mills for a period of one month for the tenting jobs in preparatory, spinning, manual cone winding, reeling and open end spinning. The training programmes were conducted in Tamil in 10 mills, Kannada in 1 mill, Malayalam in 6 mills and Hindi in two mills.

A NEW METHOD OF YARN HAIRINESS REDUCTION BY AIR SUCTION DURING CARDING

Majid Mirzaei, Ali Akbar Gharehaghaji and Mohammad Zarrebini, Textile Research Journal, December 2012, Vol 82, No 20, pp 2128-2012. Yarn hairiness is generally characterized by the extent of fibres protruding from the main body of a yarn. A new method for the reduction of yarn hairiness is presented in this article. The method deals with attaching a simple effective air suction system to the web detaching zone of a conventional carding machine immediately behind crushing rollers. A pair of grooved rollers was also placed between the crushing rollers & calendar rollers over the web. The slivers produced using the new method was reported to be almost free from dust or short loose fibers. Yarn properties such as hairiness, tenacity, elongation at break and evenness were evaluated. The ring-spun yarn produced using the new method was termed as Vacuum Cleaned Carded (VCC) yarn, due to the removal of the short fibers by air suction. Four types of VCC yarns (yarn A, yarn B, yarn C and yarn D) were produced with various air suction pressures and grooved roller status. The spinning conditions maintained in producing the various yarn samples are given Table 1. Properties of VCC yarns were compared with those of conventionally produced reference yarn samples (Yarn E). The results showed that the VCC yarn B is superior in all the major quality attributes. The hairiness of optimum VCC yarn is lower by approximately 20%, while its tenacity, elongation at break and evenness were significantly better.
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VCC yarn B also exhibited better spinning stability than the reference yarn. Table 1 Spinning conditions maintained
Yarn code A B C D E Air suction pressure (Pa) 441 667 667 667 No air suction Grooved roller status Rotating Rotating Stationary Stationary (slot)* Reference yarn

* Spun using a slotted stationary tube instead of designed air suction unit. - R.S.Vignesh Balaji Spinning division

WANT TO ENHANCE YOUR COMMERCIAL EFFICIENCY? ARE YOU REALLY GETTING A COMPETITIVE PRICE?
TO KNOW, PLEASE PARTICIPATE IN SITRAS...

Online survey of raw material cost and yarn selling price (Monthly survey)
SITRA launches a unique Online survey of raw material cost and yarn selling price from April 2013 Salient features of the survey This Online survey is the first-of-its kind from SITRA It will cover mill-wise and count-wise yarn selling price (YSP) and corresponding raw material cost (RMC) (Clean material) as well as yarn quality. Each participant mill can submit these
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data for up to 10 counts. The survey report (in pdf) will be uploaded in the web portal before 21st of every month, which can be viewed at any time. The past reports can also be viewed at any time. It would enable a participant mill to compare its RMC, YSP, Net out-put value (NOV) as well as yarn quality with other mills every month. Trend in the movement of YSP and RMC between months (for popular counts) will be highlighted every month. Data entry is made very simple. It will take only 15-20 minutes to enter one month data, that too any time during the 1st to 7th of every month. In due course, the online survey will cover some other costs and operational parameters like raw material quality, capacity utilisation, count-wise conversion cost, etc. The identity of the participant mills will be kept confidential. A nominal fee will be collected from the participant mills.

For fur ther details , mills ar er equested to visit further details, are requested our w eb por tal we portal http:// rmcysp.sitraonline.org speciall y designed f or this pur pose purpose specially for
THE SOUTH INDIA TEXTILE RESEARCH ASSOCIATION (SITRA)
13/37 , Avinashi Road, Coimbatore Aerodrome Post, Coimbatore - 641014 Phone: 0422 - 2574367-9, 4215333, 4215322 (Direct) Fax: 0422 - 2571896, 4215300 E-mail: l&c@sitra.org.in, sitraindia@dataone.in Web site: www.sitra.org.in

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ANNUAL CONSULTANCY SERVICE (ACS) FOR HUMIDIFICATION PLANTS AND COMPRESSORS

Mills are aware of the various services being offered by the Engineering division of SITRA. It has now initiated the above new service for the benefit of spinning mills. Humidification plants account for about 15% to 20% of the total power consumed in spinning mills, while air compressors account for about 6%. A modern spinning mill of 25,000 spindles consumes about 1,50,000 units of electricity per month for Humidification alone and about 45,000 units for air compressors. Use of compressed air is increasing day-by-day in textile mills leading to increase in energy consumption. Studies reveal that the efficiency of the compressed air system is below 20%, with 80% of the energy utilized for generating compressed air being converted into heat energy. So it is vital to reduce the losses in compressed air. Towards this, SITRA has conducted many studies on the energy consumption of air compressors. It is found that many mills are not earnest about monitoring the energy consumption pattern, which leads to huge losses. A machinery manufacturers claim of air consumption of individual machines and the measured actual consumption varies widely. This apart, there is a wide variation amongst mills in the consumption pattern after one or two years, due to the maintenance practices followed and care taken to arrest air leakages. Improper maintenance and the inability to realize the resultant energy loss leads mills increase the compressor capacity. Analysis of the date generated through SITRA Energy audits show that there is huge potential for energy savings in the humidification system and air compressors used in textile mills. Keeping the above in mind, SITRA is introducing an exclusive service - Annual Consultancy Service (ACS) - for humidification plants and compressed air system which will provide continuous and long term benefits to the mills.
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Scope of the service Humidification system Air flow and distribution analysis - This study includes the actual quantity of air handled by the supply air plants and exhaust air plants Air washer efficiency analysis Heat load analysis - Based on the heat load analysis carried out in all departments, the standard power required for the humidification system namely supply, pumping and exhaust are derived and compared with the existing humidification power. Plant motor loading analysis - The loading pattern of the supply air fan motors, exhaust air fan motors and pump motors are analyzed. Temperature and RH% pattern analysis - Pattern of temperature and RH% inside the departments of the mill is analyzed. Compressed air system Study on air leakage in main line and machines Air line pressure drop analysis in compressor Compressor loading / unloading pattern and saving potential Details of the Annual Consultancy Service (ACS) Contract details The contract period will be for twelve months. SITRAs Technical expert will make 3 visits to mills during the contract period. Detailed study will be made on the first visit for 2 days and a report about the performance and energy saving potentials of the plant will be submitted. Subsequent visits, each of one day duration, will be in the 6th and 9th month of the contact period.
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SITRA will provide support for the new additions / modifications on the humidification and compressor plants, if any required by the mills during the contract period. While the mill should take the responsibility to implement the various suggestions given by our technical expert in the report, SITRA will evaluate / assess the benefits / savings due to the implementation along with the mill technicians. The contract will be effected after the receipt of full payment

Charges The Annual cost for the contract is as below. Mills with spindleage up to 25,000 - ` 20,000 Mills with spindleage between 25001 and 50000 - ` 0.90/ - per spindle. Mills with spindleage above 50,000 - ` 0.80/- per spindle. Actual Travelling and halting expenses of our technical expert will be charged extra during the mill visits.

SITRA News