1

Retrofits & Accessories for

Textile Process Houses from

A.T.E. Enterprises Private Limited

2

Retrofits &

Accessories

Save Cost

Improve Productivity

Improve Quality

3

Critical challenges of Indian processing units

Productivity

Quality

High cost of capital

Rising energy costs

Water scarcity

Critical

challenges

faced by Indian

processing

units

4

Retrofits and utilities from A.T.E.

A range of retrofits

and utilities that will

result in :

Enormous saving in energy

Improved productivity

Improved quality

with a substantially low investment

and fastest ROI!

5

Retrofits &

Accessories

Save Cost

Improve Productivity

Improve Quality

Improve Quality

Improve Productivity

6

Mahlo Atmoset SMT-12 is an online

moisture control and monitoring

system, that controls the steam input

in drying cylinders by optimising the

drying process, thus saving heat

energy (30%-50% saving in steam

can be achieved) and results with

consistent quality output.

Payback in just 8 months!!!

Reference: Alok (Vapi), Auro (Baddi), Welspun (Anjar), GHCL (Bhilad)

Sa

ve

en

erg

y

Sa

ve

co

st

Steam consumed per kg. of fabric

processed on drying range (without

Atmoset SMT-12)

1.2 kg

Steam saved per kg. of fabric

processed (considering just 25%

steam saving with Atmoset SMT-12)

0.25 kg

So, steam saved after processing 21

MT (or 80,000 meters) of fabric per

day

0.25 21000

= 5250 kg

Considering 25 days working per

month, steam saved per month

1,31,250

kg/month

Cost of steam saved per year* Rs.

25,20,000

Cost of Mahlo Atmoset SMT-12: Rs.16,25,000**

So, ROI = 7.74 months ~ 8 months (*Cost of steam considered @ Rs.1.6/kg)

Mahlo - Atmoset SMT 12

**Prices of equipment are indicative and are subject to change

7

Payback in just 2 months!!!

Reference:

The shell and tube system

recovers heat energy from waste

water and uses it to heat fresh

water, while maintaining

constant process water

temperature by means of a PLC

attached to the system.

Input parameters Output parameters

Waste water 20 m3/hr Fresh water inflow: 20 m3/hr

Wastewater @ 80C

cooled to 41.15C

Fresh water @ 25C; heated up

to 63.57C

Thermal efficiency: 886.1kW

Fuel used: Firewood (calorific value of 3000 kcal/kg)

Cost of fuel: Rs. 3/kg

Total working hours per year: 6000

Fuel saving per year: 2177 MT

Cost of fuel saved: Rs. 65,31,900

Cost of Luwa water to water heat recovery system =

Rs. 8,50,000**

So, ROI = 1.56 months ~ 2 months*

Sa

ve

en

erg

y

Sa

ve

co

st

Luwa - water to water heat recovery system

**Prices of equipment are indicative and are subject to change

N.B: Performance depends on constancy of input parameters and maintenance

8

Payback in just 15 months!!!

Reference: Ruby (Khopoli), Oswal F.M. Hammerle (Kolhapur), GHCL (Bhilad)

A retrofit for the Osthoff singeing

machine for objective measurement of

the hairiness of the fabric for proper

control of the singeing process by

regulating gas intensity as per the

fabric hairiness, resulting in uniform

hairiness across the batch. Regulation

of gas intensity also results in saving of

gas.

Without

online

hairiness

tester

With online

hairiness

tester

Consumption of gas in kg/hour 15 11.5

Cost of gas in Rs./hour 945 724.5

Cost of gas in Rs./day 18,900 14,490

Cost of gas in Rs./month 4,72,500 3,62,250

Cost of gas in Rs./annum 56,70,000 43,47,000

Net savings (Rs./annum) 13,23,000

Cost of online hairiness system: Rs.1,625,000**

Cost of propane considered @ Rs. 63/kg

Working hours considered @ 20/day

Working days considered @ 25 days/month

Imp

rove

d q

ua

lity

& c

os

t s

avin

gs

Osthoff - online hairiness tester

**Prices of equipment are indicative and are subject to change

9

A robust, third generation retrofit, made

of metal foam for the pre-dryer installed

on the CDR to reduce the moisture on

the fabric before it enters the hot flue, to

avoid migration of dyestuff. Varying gas

intensity with actual temperature

requirements (in the range of 600 to

800 C) results in saving in gas to the

extent of 25-30% as compared to

ceramic pre-dryers.

Save e

nerg

y

Save c

ost

Payback in 50.4 months

Monforts - infrared pre-dryer for CDR

**Prices of equipment are indicative and are subject to change

Reference: Arvind (Ahmedabad), Auro (Baddi), Alok (Vapi)

Parameter Old New

Consumption of gas in kg/hour 33 kg 20 kg

Cost of gas in Rs./hour Rs. 2,079 Rs. 1,260

Cost of gas in Rs./day Rs. 41,580 Rs. 25,200

Cost of gas in Rs./month 1,039,500 630,000

Cost of gas in Rs./annum 12,474,000 7,560,000

Net savings in Rs. 4,914,000

Cost of infrared pre-dryer for CDR: 295,000 or Rs. 20,650,000**

Cost of propane considered: Rs. 63/kg

Working hours considered: 20/day

Working days considered: 25/month

Return on investment: 50.4 months

10

Retrofits &

Accessories

Save Cost

Improve Productivity

Improve Quality Improve Quality

Save Cost

11

Impro

ve p

rod

ucti

vit

y

Im

pro

ve p

rofit

Description

A residual moisture measurement instrument for drying ranges that controls the degree of dryness of the product by means of dryer speed based on the residual moisture

Benefits

Improved productivity

Energy optimisation

Optimal residual moisture for subsequent processing

References

Alok (Vapi), Oswal Hammerle (Kolhapur), Vardhman (Bhopal), Auro (Baddi), Birla Century (Bharuch)

Mahlo textometer RMS can be used in stenter, pad steam and pad

dry, and CBR.

Mahlo - textometer RMS

12

Description

This advanced textile digital metal detector is highly sensitive to all magnetic and non-magnetic metals. The compact and robust construction of this metal detector with plug-and-play settings ensures a high degree of protection (IP 65 RC version)

Benefits

Highly reliable at a

wide range of speeds,

as high as 600

m/minute

Can detect ferrous and

non-ferrous metal as

small as 0.8 mm.

Prevents damage to

rubber rollers and

fabric

Higher machine uptime

Higher productivity

Higher safety

Better quality output

References

Alok (Vapi), Oswal Hammerle (Kolhapur), Vardhman (Bhopal), Auro (Baddi), Birla Century (Bharuch), Jakharia (Boisar), Mandhana (Boisar), etc.

Impro

ve p

rod

ucti

vit

y

Im

pro

ve p

rofit

CEIA metal detectors can be used in shearing, calendar, shrinking

singeing machines, dye padder and CBR

CEIA - bar metal detector

13

Description

The THS 21 conveyor satisfies the most stringent requirements for functionality, compact construction, accuracy and reliability of response in dealing with accidental metallic contamination of products

Benefits

Very high sensitivity to

ferrous and all

magnetic metals

Detection sensitivity

compliant with the

textile industry

Standards

Digitally-adjustable belt

speed

Structure and metal

detector in AISI 316L

stainless steel

High flexibility: all parts

completely reversible

and modular

References

Welspun (Anjar), SEL (Punjab), Trident (Budhni)

Impro

ve p

rod

ucti

vit

y

Im

pro

ve p

rofit

CEIA metal detectors can be used in a multitude of textile related

applications

CEIA - conveyor metal detector

14

Description

Comprising of Ecomat AML, textometer RMS and Permaset VMT, The ecopac EMC-12 monitors and controls exhaust air moisture, residual moisture, and fabric heat setting temperature respectively, resulting in improved productivity and energy optimisation

Benefits

Improved productivity

Energy optimisation up

to 16%

Consistent quality

References

Alok (Vapi), Oswal Hammerle (Kolhapur), Vardhman (Bhopal), Auro (Baddi), Birla Century (Bharuch)

Impro

ve p

rod

ucti

vit

y

Im

pro

ve p

rofit

Mahlo ecopac EMC-12 can be used in stenters

Mahlo - ecopac EMC-12

15

Description

An innovative technology which is CE certified and available in different capacities, to provide moisture-free compressed air to pneumatic systems on various machines.

Compressed air cools the incoming air and separates the moisture via a timer-controlled electronic drainage wall

Benefits

Higher machine uptime

Higher productivity

Long life of pneumatic

systems

Less maintenance

References

Manan Cotsyn (Boisar), Valiant (Boisar), Sutlej (Bhilad)

Impro

ve p

rod

ucti

vit

y

Im

pro

ve p

rofit

Advance Cooling - compressed air dryer

16

Description

CE-certified and available in different capacities, panel ACs help protect costly electronic equipment from the heat generated by drives in the electrical panel as well as dust and humidity

Benefits

Higher machine uptime

Higher productivity

Long life of electronics

Less maintenance

References

Alok (Vapi), Ruby (Khopoli), BRFL (Boisar), Kothari Exports (Kolkata), Khosla (Mumbai), etc.

Impro

ve p

rod

ucti

vit

y

Im

pro

ve p

rofit

Advance Cooling - panel air conditioner

17

Description

A unique system that is CE-certified and available in different capacities to maintain constant temperature of the dye liquor and chemicals in the trough. This water chiller circulates chilled water around the walls of the trough to maintain its temperature at a desired level

Benefits

Improved productivity

Evenly dyed fabric

Reduced re-dyeing

Minimum tonal and

shade variations in the

dyed fabric

References

Ruby (Khopoli), Auro (Baddi), Raymond UCO (Yavatmal)

Impro

ve p

rod

ucti

vit

y

Im

pro

ve p

rofit

Advance Cooling - water & oil chiller

18

Retrofits &

Accessories

Save Cost

Improve Productivity

Improve Quality

Save Cost

Improve Productivity

19

Impro

ved q

uality

Im

pro

ve p

rofit

Corino - beating & brushing systems

Benefits

Improves productivity

Improves quality

Energy optimisation

References

Alok (Vapi), Oswal Hammerle (Kolhapur), Vardhman (Bhopal), Auro (Baddi), Birla Century (Bharuch)

Description

A compact unit with the provision to

attach different brushing or beating

systems.

Used in singeing machines,

CBRs, and printing machines

20

Impro

ved q

uality

Im

pro

ve p

rofit

A.T.E. - rotary drum filter

Benefits

Improves productivity

Improves quality

Reduces maintenance

References

Alok (Vapi), Indocount (Kolhapur), Himatsingka (Hasan), Birla Century (Bharuch), GHCL (Bhilad), Aarvee Denim (Ahmedabad), Welspun (Anjar)

Description

A compact unit with a brushing system

for removal of fluff from drums without

using water

Used in singeing / desizing

systems, CBRs, and CRP (Caustic

Recovery Plant)

21

Impro

ved q

uality

Im

pro

ve p

rofit

A.T.E. - screen filter

Benefits

Reduces labour cost

Less maintenance

Hassle-free system

References

Chenab Textile (Kathua)

Mandhana (Boisar)

Description

A compact unit with screen type

brushing system for removal and

collection of fluff

Used in ETP inlet at preliminary

treatment stage and various

drainage outlet as well

22

Impro

ved q

uality

Im

pro

ve p

rofit

Rotovac - online dust & lint removal system

Benefits

Reduces labour cost

Less maintenance

Hassle-free system

References

Arvind (Ahmedabad), NSL Textiles (Hyderabad), BRFL (Boisar)

Description

A compact unit with a spring-type

brushing system for automatic

removal and collection of fluff

Used in rotary and flat bed

printing machines

PPT/Rotovac.pptx

23

Impro

ved q

uality

Im

pro

ve p

rofit

Monforts - chambers for stenter, pad dry

Benefits

Improves productivity at low investment

References

India Dyeing (Erode), Alok (Vapi), BJ

Textiles (Naidupet)

Description

Additional chamber with running

stenters, hot flues

24

Impro

ved q

uality

Im

pro

ve p

rofit

Montimac - rail sewing machine

Benefits

Reduces wastage of fabric

Improves fabric & stitch quality

References

BRFL (Boisar), Indocount (Kolhapur),

Shreeji Lifestyle (Dombivali)

Description

Rail sewing machine for head to

head stitching of fabric edges before

batching

25

Impro

ved q

uality

Im

pro

ve p

rofit

Corino - guidance system for digital printing

machine

Benefits

Perfect feeding and winding of fabric

with uniform tension

Improves printing quality

References

Shreeji Lifestyle (Dombivali)

Description

Compact unit that ensures uniform &

tensionless feeding of fabric to

printing machine

26

Impro

ved q

uality

Im

pro

ve p

rofit

Monforts - eco applicator

Benefits

Improves fabric quality

Reduces energy costs for drying /

increases speed

References

Not yet sold in India; numerous

installations abroad

References available on request

Description

For controlled application of

chemicals (softener, hydrophobic,

hydrophilic, stain repellants, etc)

27

Impro

ved q

uality

Im

pro

ve p

rofit

Dunline - endless rubber shrinking belts

Benefits

Uniform performance throughout the

life of the belt

No material defect

Improves fabric quality

References

Alok (Vapi), Raymond (Kolhapur), Arvind

(Ahmedabad), JCT (Pagoda), RMB

Denim (Surat), Century Denim (Indore),

etc.

Description

For fabric shrinking on shrinking

ranges

28

Impro

ved q

uality

Im

pro

ve p

rofit

Dunline - endless felts

Benefits

Designed to offer uniform performance

throughout the life of the felt; no

material defects

Improves fabric quality

References

Jindal Worldwide (Ahmedabad), Bhaskar

Denim (Bhopal)

Description

For drying & giving feel to fabric

used on palmer drum of sanforizer,

relax dryer, printing dryer

29

Impro

ved q

uality

Im

pro

ve p

rofit

Dunline - accessories

Benefits

Maintain and increase longevity of

the belt & felt

References

BRFL (Tarapur), Mandhana (Tarapur), Oswal Denim (Lalru and Bhopal), Nahar (Lalru), Bhaskar Industries (Bhopal), Indocount (Kolhapur)

Description

Topline belt safe compound

Topline safe wash

Topline belt lube

Topline paralel gauge

Topline surface contact thernmom

30

Impro

ved q

uality

Im

pro

ve p

rofit

MAG - textile testing instruments

Benefits

Quality assurance

Support customization

Calibration & test certification

Provision of AMC and OMC

References

E I Dupont India (Hyderabad), Alok

(Silvassa), Morajee (Nagpur), Alps

(Ghaziabad), Grasim (Bhiwani), Shree

Sidvinayak Texco (Ludhiana), Shree Balaji

(Ludhiana), Pratap (Ambala), Ahuja Cotspin

(Punjab), Garg Acrylics (Punjab), KPR

(Tamil Nadu), Keshar Multi Yarns (Kolkata),

Vishnu Cotton Mills (Kolkata)

Description

High quality textile testing instruments at

affordable cost

31

Impro

ved q

uality

Im

pro

ve p

rofit

Valence - static discharge bars

Benefits

Improves safety

Helps to improve productivity

Helps to improve quality

References

Nahar (Lalru), Tex n Nets (Gurgaon), Jain

Textiles (Gurgaon), Surya Processors

(Ghaziabad), Alps (Ghaziabad), Kudu Knits

(Ludhiana)

Description

Compact, sturdy and reliable static

discharge bars to eliminate electrostatic

charge on moving parts

32

Impro

ved q

uality

Im

pro

ve p

rofit

A.T.E. - material handling system

Benefits

Low effort transport system

Suitable for heavy loads

Trouble-free working

References

NSL (Guntur), Birla Century (Bharuch),

K G Denim (Mettupalayam), D Dcor

(Tarapur), Premier Fine Linens

(Perundurai), Trident (Budhni) and

Himatsingka Linens (Hasan), Welspun

(Anjar)

Description

Supply of all types of material handling

equipment to store and move textile

substrates from one machine to another

33

Impro

ved q

uality

Im

pro

ve p

rofit

A.T.E. - lubricants and greases

Benefits

Resists hydrocarbon washout/dilution

High load carrying capacity

Reduced sludge and deposit formation

Excellent oxidative and thermal stability

Low friction and less power

consumption

References

Description

High quality speciality lubricants which

can perform under extreme conditions

of speed, temperature & load. Different

purpose grease & oil, aerosol sprays for

wet and dry applications for trouble free

operation of machines for longer

duration

Mandhana (Boisar), Alok (Vapi), BRFL (Boisar), Valiant Glass (Boisar), Mudra Lifestyle (Boisar), Ruby (Khopoli), Arvind (Ahmedabad), Premier (Bengaluru), Himatsingka Linens (Hasan), Vardhman (Budhni), Nahar (Lalru), etc

34

Impro

ved q

uality

Im

pro

ve p

rofit

A.T.E. - textile automation control systems

Benefits

Improves the performance of old

machines

Hassle free operation

Improves production of machines

Reduces operation time

Reduces operation cost

References

Welspun Syntex (Silvassa), Bhaskar

Denim (Bhopal), Balkrishna Synthetic

(Tarapur), Indorama Synthetic (Nagpur),

Arvind (Ahmedabad), JCT (Phagwara),

Premier (Coimbatore)

Description

Complete, customized retrofit and

automation solutions for the textile

industry

35

THANK YOU