The Bombay Textile
Research Association

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Ministry of Textiles

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The Bomby Textile
Research Association

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Approved body,
Ministry of Textiles

BTRA EXPERTISE IN MAINTENANCE & PROCESSING AUDIT

EXPERTISE IN CHEMICAL PROCESSING

WIDE-RANGING TECHNICAL EXPERTISE IN CHEMICAL PROCESSING

Preparation of Green Project Reports for the process houses of desired capacity, end products with competitive edge and quality standard. Subsequently, setting the processing parameters to achieve the goal.
Preventive /Predictive / Productive /Qualitative maintenance audit of chemical processing machinery.
Lab scale developmental works pertaining to bleaching, dyeing, printing and finishing and their subsequent transfer in the bulk production on the existing machinery with adequate correlation between lab and bulk production machinery with the aim of avoiding redyeing / refinishing /rework for new shades/design/ finishes etc. and hence faster in time fulfillment of commitment on new items/order to obtain repeat order.
Evaluation of the causes for damages and subsequently their eradication/reduction and hence reduced value loss in chemical processing.
Reduction in fabric inventory in processing and after processing with suitable modification.
From the viewpoint of global market, studying the viability of existing chemical processing houses/ industry.
Conservation of water vis-.-vis reduced water pollution load and hence reducing production cost per unit and threat to environment.
Conservation of thermal energy and power thereby reducing production cost per unit.
Establishing the process control parameters on various machines / sections for the desired end products.
Establishing the quality control parameters on intermediate processes to obtain the desired final end products on all blends and unions of woven and knitted fabrics.
In-house training to increase the knowledge and skills of technical personnel according to the plant set up and products being manufactured to make them more effective and hence greater profit contributor.
Trouble shooting to eradicate on-going irritating problems in chemical processing related with bleaching, dyeing, printing, finishing, manufacturing etc.
Diagnosis of chemical processing industries/process houses for evaluating the existing operations and their subsequent upgradation by newer technology/ modification in existing conditions /set up to maintain international compatibility in quality, consistency, production rate, cost per unit, etc.
Improvement for the high value addition at highest profit margin.
Establishing processing parameters for the products of new markets and hence increased business opportunity

Evaluation of -

Physical and chemical properties of textiles as specified by AATCC, ISO, Japanese, BIS Test Standards.
Purities of textiles dyestuffs, chemicals, auxiliaries.
Textile dyestuffs, chemicals, auxiliaries for the presence/absence of banned chemicals for their permissible limits. Eco-Testing according to the requirement of Branded Retailer.

Benefits Derived By the Industry

Increased profitability
Increased right first time rate
Improved cash-flow
Improved reputation in retail supply chain
Enable to keep you ahead of your competitor and stay there
Increased job satisfaction for the people of entire supply chain

WATER CONSERVATION AUDIT

WATER CONSERVATION

Textile wet processing is a water intensive one. It also generates more effluents that are harmful to the environment. BTRA conducts audit on water consumption in process houses. This audit is most sought after by the industry.

What BTRA Audit does?

Detailed shop-floor studies are undertaken to explore the areas for water conservation
Recommends suitable preventive/corrective measures
Provides required technical assistance in implementing the recommendations
Conducts reconciliation studies to indicate / verify the savings achieved, after the implementation of the recommendations
Offers suggestions to reduce effluents load

Benefit to the Industry

Reduction in processing cost
With the help of BTRA, many textile units have achieved a direct saving of water consumption between 18 % to 55 % depending upon the working conditions such as type of product mix, processing conditions, machinery set-up, etc. In addition to direct saving, water conservation measures lead to
Reduction in waste water treatment cost
Reduction in thermal energy consumption
Reduction in electrical energy consumption
Reduction in pollutants load

ETP ADEQUACY AUDIT

ETP ADEQUACY

This is most required activity in recent trends and pollution control requirements. This audit is done to assess the Existing ETP plant set up and performance against the pollution control board requirement.

What BTRA Audit does?

Detailed study quantity and quality of effluent generation from process house
Checking of ETP set up and retention time adequacy against the pollution control requirements
Performance of the Existing ETP and level of the pollution reduction stage wise
Provides required technical details ( know how ) for improvement through the training and technical consultancy
Offers suggestions to reduce the effluent load from process house
Facilitation of the process of any modification in the ETP

Benefit to the Industry

With the help of BTRA, many textile units have achieved a direct saving of water consumption, improvement in chemical management system in the process
Increase the mills compliance to the pollution control requirements
Reduction in water consumption
Reduction in waste water treatment cost
Increase in water recycling and reuse
Reduction in pollutants load

THERMAL INSULATION AUDIT

The audit programme of BTRA regarding quality, machinery, energy and water are very popular among mills. Now, BTRA has initiated one more audit viz., ‘THERMAL INSULATION AUDIT’.

The salient features of this audit are as follows:

It is very specific in nature
Easy to implement suggestions
Payback period is shorter
In textile wet processing, there is a network of pipelines [carrying steam / condensate / thermic fluid] supplying thermal energy to the departments. These pipelines are insulated at the time of installation to minimise heat loss. But after a certain period, the condition of the insulation starts deteriorating, causing lower insulation efficiency. This leads to continuous drain of heat energy from the system and hence, additional consumption of steam, electricity and fuel to meet the given requirement of thermal energy from the departments.

What BTRA Audit does?

Inspection of the existing insulation of hot lines with the instrument
Inspection of the existing insulation of hot lines with the instrument
Evaluation of Insulation Efficiency
Identification of areas of damaged insulation causing higher losses
Calculation of savings with payback period due to replacement of damaged insulation
Recommendation of suitable insulation material
Recommendation of optimum insulation thickness

Benefit to the Industry

Fuel consumption reduced by preventing unnoticed wastage of heat through the damaged insulation
Low investment on re-insulation, as the industry has to replace only the damaged portion of insulation identified in the insulation audit

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