BTRA Expertise in Processing & Maintenance 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-à-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
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
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 processing cost
- Reduction in waste water treatment cost
- Reduction in thermal energy consumption
- Reduction in electrical energy consumption
- Reduction in pollutants load
Thermal Insulation Audit
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
- Computation of heat loss from each point of inspection at various locations
- 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