Industry

A small scale industry of Dyeing & Printing of gray cloths in Gujarat is having a plant capacity of 12500 meter / day.

Process

Grey Cloth Inspection :-Cloth is separated according to different qualities as per requirement.

Scouring :- To remove Oils, Fats, Waxes together with other impurities by using detergents, alkali, completing agents, dispersing agents, reducing agents etc.

Bleaching :-To remove natural impurities by bleaching chemicals, surfactants, fluorescent Whitening agents and white - R to make the fabric ready for dyeing and printing.

Dyeing :-The fabrics is to be dyed & then subjected with dyes & auxiliaries at 120°C to 130°C in dyeing machine along with water & heat transfer through steam & thermic fluid which undergo washing & simultaneously cooling of the fabric from 120°C - 40°C than heat setting & Ph balance is going on.

Printing :- The fabric is printed by dye printing & pigment - printing process involves pretreatment, printing, drying, fixation & washing.

Ageing :- The Ageing Treatment is given to the fabric to fix the color permanently on cloths.

Finishing & Heat Setting :-It is for improving the feel, volume, softness and facilitate the durability to the fabric by chemical agents as well as by finishing auxillaries.

CP-Programme

After complete study of process as per CP-methodology potentials for CP-options were developed and evaluated afterwards. After economical and technical feasibility analysis few options were suggested to industry and the results that we got are tremendous and very valuable for industry in current situation prevailing in the Global Market.

CP-Results

• During Scouring and Whitening of the fabric, the chemicals added are optimised by implementing CP option. It eliminates the problem of COD, BOD, S.S concentrations in ETP. With investment of Rs.1,25,000 (one time) gives saving of Rs.4,05,000 / year.
  
  
• Spent liquor is generated after the bleaching and scouring processes. It contains approx. 30% excess chemicals. To reuse these chemicals spent liquor is recycled to the same process in subsequent batches by implementing CP option. With investment of Rs. 1,00,000 (one time) that saves 7,18,200 Rs./ year and this also reduce COD load in ETP.
  
  
• During the steam generation process, TDS of water inside the boiler increases. To improve the life of boiler CP option suggested is to use low TDS water with investing Rs.7,00,000 gives saving of 7,20,000 Rs. / year.
  
  
• During Washing operation when machine is not running and labour is not stopping the valve of water supply line so to control this, CP option suggest to go for the installation of Solenoid Valve coupled with mechanical and electrical connection with investing Rs. 50,000 that saves 15,525 Rs. / month.
• Screen is used for the printing process and after completion of printing process the screen is washed with the water. To reduce the water consumption, CP option is to go for the High Pressure Jet Machine by using treated effluent. This needs investment of Rs.5,000/ 5 High Pressure Jet Machine which reduce the consumption by 10,50,000 Lt/ Month with saving of Rs.6,037/ month.
  
  
• CP options were implemented successfully with saving of Rs.20,00,000/ year and environmental savings like Reduction in COD, TDS, Water and Energy etc.