Ankita Gupta

Shivangi Katiyar
Raj Shankar Chaurasia
 Looms

Powerloom Handloom

Shuttle Shuttle less

loom loom
 In the present conventional shuttle looms, it is necessary to pass

Problems associated
a shuttle weighing around half a kilogram through the warp

with shuttle looms

shed to insert a length of weft yarn which weighs only few
grams.

The shuttle has to be accelerated rapidly at the starting of

picking cycle and also to be decelerated, stopped abruptly at the
opposite end. This process creates heavy noise and shock and
consumes considerable energy.

The probability of weft way fabric defects are high to the tune
of 70% in shuttle looms. Even in automatic shuttle looms there
is a chance of transfer failures and weft lashing in defects.
Air jet looms Rapier looms Water jet looms
Uses short quick bursts of Uses a hook system
attached to a rod or metal Use the same principle as
compressed air to propel
band to pass the pick the air jet looms.
the weft through the shed.
across the shed. Uses pressurized water to
Fastest method of propel weft.
weaving. Interlaces 700 picks per
minute. Water power is cheaper
Amounts of compressed and easily available.
air required & its
complexity makes it
uneconomical.
 Industry is electricity intensive and requires power 24X7.
Requirement

Invested in a hybrid model of renewable energy using both wind & solar energy.
Tata power solar team provides a detailed engineering solution.
The structures were custom designed to withstand high winds without creating any impacts on the
Solution buildings & rooftop.
Rooftop design saved nearly 10 acres of land space.

Machinery runs on 100% renewable resources

25% of electricity requirement is fulfilled by solar and wind energy.
Benefits
 Weaving preparation and weaving technologies employ preparation machines of warping,
sizing and weft preparation; weaving machine; and post weaving process desizing process.

All process technologies require high amount of electric and heat energies.

Warping machine and weft preparation machine consume only electric energy with reasonable
level of environmental load

Whereas sizing and desizing processes consume high level of heat energy beside electricity and
result high degree of environmental load.

Warp and weft preparation machineries are electric energy-consuming systems.

Their energy efficiency might be improved with controlled maintenance, cleaning, efficient
engines and driving systems, and other mechanical equipment on the machines.

Achievements of waste yarn decrease on these processes result in improvements in the

sustainability degree of the weaving preparation processes.
 Sizing process of weaving preparation phases is the most important process from the view of
sustainable weaving technology.

Reduction of heat energy consumption and environmental load of the sizing auxiliary are two
key factors to improve sustainability feature of the sizing process.

Reduced steam temperature utilization and cold sizing agent use are offered possibilities for
decrease of environmental load of the sizing process.

Besides the continuous improvement attempts on the environmental load of sizing process,
cutting off the whole process via utilization of high strength of warp yarns is another
revolutionary and challenging option.

To achieve efficient size- free weaving, superior quality of warp yarn is required.
 After the completion of the weaving process, size of the fabric needs to be removed to
ensure the quality of consecutive finishing processes.

Desizing process consumes large amount of discharged water, which is about 40-50% of
the total wastewater release of the plant.

Most of the size removed during desizing is discharged in effluent form and causes high
level of environmental load.
 Distillers dried grains (DDGS), the co products of corn ethanol production, were used
as a textile sizing agent on cotton, polyester and polyester/cotton blends in an effort to
find inexpensive and biodegradable alternatives to sizing agents such as poly(vinyl
alcohol) that are currently used.

Easily degradable in wastewater sludge.

Although DDGS is an inexpensive, biodegradable and abundant co-product, it has

limited industrial applications. DDGS is a mixture of carbohydrates, proteins and oil
which are used as sizing agents or as size additives.

The DDG size provided a similar increase in Roving strength, better abrasion resistance,
and substantially higher biodegradation than PVA.
http://digitalcommons.unl.edu/cehsdiss/167/
http://digitalcommons.unl.edu/cgi/viewcontent.cgi?article=1168&context=cehsdiss
http://pubs.acs.org/doi/abs/10.1021/sc4002017
 Bio-desizing enzyme systems are based on amylase that solubilises starch in sizing
preparations. Conventional bio desizing systems operate at temp 55-65 degree centigrade.

Desizing Conditions:

Advantages of using enzymes:

Replacing acids, alkalis or oxidizing agents in fabric desizing.

Use of enzymes in the tanneries to reduce the use of sulfied .
Less time required.
No damage to the fibre.
Closely constructed fabric can be easily desized due to the effective enzyme action.
https://www.slideshare.net/NadeeraDodamgoda/enzyme-washing
http://www.fibre2fashion.com/industry-article/2477/bio-processing-of-textiles?page=5
http://www.fibre2fashion.com/industry-article/1731/bio-processing-in-textiles?page=9
http://eprints.hud.ac.uk/13814/1/Power01_-_2012_Sustainable_developments.pdf
 From the view of sustainability frame, knitting technology has better sustainability feature than
woven fabrics.

Seamless knitting technology is a new technology. It requires minimal or no cutting and sewing
process to complete and entire garment.

This innovative technology promises elimination of post labour work, more comfort and better fit
to the consumer by eliminating seams.

It offers lower energy consumption and less environmental load as heritage of knitting technology.

Advantages of the seamless technology can be listed as saving on labour, time, cost, and
environmental load where the lowest possible level of waste disposal, reduced need of fibre and
yarn.
 https://in.pinterest.com/pin/529243393688791708/

Seamless Knitting Final Seamless Knitted

Garment Production
Machine Garment
http://www.santoni.com/en-macchine-item.asp?idf=1 http://www.innovationintextiles.com/ispo-success-for-seamless-specialist/
 A new technical approach by Mayer & Cie; circular knitting
machines that spin as well.
Objective is to save energy; consumes significantly fewer resources.

The normal sequence is that finished yarn runs into the circular
knitting machine and is processed there.
But Spinit works with the semi-finished yarn(yarn that has just left
the prespinning machine).
In order to turn the semi-treated yarn into finished yarn, it needs
to pass through ring spinning machines, which take up space and
use a lot of energy.
In Spinit, the semi-treated yarn(3 to 5 mm thick) passes straight
into the circular knitting machine, where it is spun and then
knitted.
Depending on the energy and labour costs in a given country, one
kilo of knitted fabric can be up to a quarter less expensive than the
same item made conventionally.

http://www.indiantextilemagazine.in/knitting/sustainable-spinit-technology-from-mayer-cie-replaces-entire-machine-park/
 BOOKS

Textiles and Clothing Sustainability: Sustainable Technologies

edited by Subramanian Senthilkannan Muthu

Roadmap to Sustainable Textiles and Clothing: Eco-friendly Raw

Materials ...
edited by Subramanian Senthilkannan Muthu