IoT based Energy & process management solution

THE INTEROPERABLE SYSTEMS IN TEXTILE INDUSTRY – THE ROLE OF IoT.

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Indian Textile Industry hits the 5th Millennium: The archaeological surveys and studies have found that the people of Harrapan civilization knew to weave, and the spinning of cotton four thousand years ago. Apart from the Bronze age civilization, There was a proof for textile trade in India during the early centuries, A block printed and resist-dyed fabric, whose origin is from Gujarat was found in the tombs of Fostat, Egypt.

Needless to say that, we are very old in the business, but then it was very much less compared to now. The textile industry is now is not just manufacturing of yarn, fabrics, and textiles for clothing, carpets but, further classified based on distinct sections such as research, design, manufacture, and distribution.

What is the Indian Textile Industry weaving now?

Name anything in the Textile industry, Either India was already there or India was the only one there. The oldest sector & the greatest contributor to our economy has set benchmarks in various ways.

The growth of the Textile industry looks promising with the increase in market demand worldwide for textile products. Sneak into the facts & figures to understand what is weaving in the Indian Textile Industry now.

textile facts & figures in India

Although the industry is well poised to grow at an annual rate of 15% but going ahead will be tough unless the industry acquires technological know-how related to ” From Connecting Each Module to Automating the Whole Process”.

The Risks!

Besides the inferior technology, the industry has been persistently facing various external issues which need an immediate attention. Major issues are:

  • Skill gaps and the shortage of skilled manpower as the process is yet to be automated
  • Very high-interest rates
  • Lack of sustained demand from the user sector
  • Import of second-hand machinery whose life cycle is less & the average energy consumption/cost is more.
  • The Process which has to be measured, monitored & controlled for avoiding unnecessary variable costs & eventually gaining more profits.
  • The knowledge for the owners to Invest in the technology.
Is the Fashion Industry still running Old-fashioned?

The process involved in the textile industry is found to be highly complex with the beginning of research, design, development to finished products. These processes are performed using a wide range of machines such as spinning, weaving, dyeing, printing, finishing and manufacturing fabrics.

the basic process modules of a textile factory

It is completely process-based where each & every stage has the power that will lead to a large impact on the productivity and profitability during any obstructions. We need keen monitoring at every stage in complex processes such as textile that demands an Integrated system to measure the precise details of each machine.

An interoperable platform for Textile Factories?

The textile industry is found to be the leading sector that needs immediate digitalization as it is dependent on precise details of equipment functioning, management of dyes, and monitoring of raw materials. Further, it is necessary to consider the deviations occurring in the industry from Standard Operating Conditions to minimize the revenue losses. This suggests the need to effectively utilize technology in the textile industry either it is IIoT based products or the IoT solutions.

Energy & Process Monitor:

Measuring Energy & Process parameters from a single device

A single device to monitors the electrical & Process parameters & suggest the preventive measures while analyzed using an Energy & Process Management System.

Link to elmeasure products
Salient Features:
  • Real-time monitoring and reporting
  • A Composite system with EMS and PEMS
  • Desired reports like, Doff wise, shift wise, count wise, production, energy, UKG
  • Speed Vs Kw curve, trends, bar graphs, comparisons
  • Alerts on higher UKG, lesser production, utilization & power fluctuations.
  • Maintenance alerts based on run hours production cost analysis – Cost Audits – Energy Audits
An Energy & Process Management System at 50001:2011 standards:

Interoperability is the concept evolved by the way Internet of Things (IoT) based solutions works, which is generally defined as a network of physical objects with internet connectivity for the communication between the devices and the system.

The optimum productivity is achieved only when the system is process oriented & the process is automated!

Process controlling

Industrial Internet of Things (IIoT) is found to be a gateway between the computing technologies, cloud, mobile machine learning, and industrial infrastructure to help industries elevate their productivity and efficiency. IIoT solutions is a world of monotonous throng with networks, sensors, operating equipment and devices in comparison to smart home appliances. The information collected from the devices will be used to analyze, monitor, maintain high performance and efficiency in industrial applications such as production and maintenance.

Further, data collected can be directly uploaded to a cloud server using products like EPC through various communication protocols.

It is necessary to utilize process management systems in textile industries to monitor and receive the real-time data for the effective decision-making process.

These solutions can help in preventive maintenance to reduce the overall energy consumption and to provide a sustainable environment.

Enhance Life & Economy in Textile industry:

In several textile industries, sensors were placed in washers, dryers, and other equipment to improvise their performance by attaining real-time data, in addition to detecting failure of equipment thereby reducing the downtime.

  • Specific energy consumption of heavy loads: Calculation of section-wise energy consumption against product output
  • Performance check and periodic maintenance: Verification of equipment data with respect to rated specs
  • Monitoring of cyclic operation of spinning unit (Ring frame): Number of Stoppages with duration during doffing; Energy comparison of various ring frames bis-à-vis product outputs (Ring UKG); Different Yarns count and specific energy consumption (UKG) per Ring frame
  • Identifying the idle running of the machine.

There are multiple Case studies on Pacific Textiles, Getzner Textile, Everest Textile industry indicates the need for their rapid transformation towards digital revolution to improvise their operations & productivity.

Frequent challenges observed in incorporating IoT in the textile industry:

Recent studies on IIoT indicates a rapid growth towards automating textile industry from the initial stages of development to production, storage, and marketing to improve the time to market (TTM). However, practical implementation of IoT in the industry will undergo various challenges while redefining the textile industry as listed below:

  • IoT being a network of physical objects, it is necessary to ensure appropriate connectivity of weaving machines with huge bandwidth through Ethernet.
  • A large amount of structured/unstructured data will be available on the integration of IoT and it is necessary to manage these voluminous data.
  • Suitable IoT management platforms that are compatible with ERP, administrative and management systems are required.
  • Data integrity and confidentiality of the data transferred needs to be considered with the integration of IoT platforms.

“How about your process automation + RoI in < 6 Months” with a system customizable for any industry as per the needs?

Role of IoT in various industries

A simple and easy-to-use IoT platform from ELMEASURE® can be used to perform periodic assessments which stores, monitors and measures to perform detailed analysis for any industrial challenges.

This is a single platform that can be customized based on the industry’s process whether Food Processing, Textile, Engineering, Automobiles, etc.

Link to Elmeasure Solution

For more details, visit: https://bit.ly/2PSQTjl

Whitepapers on Textile Process Management: https://bit.ly/2D7bs8U

Case Study of Amaravathi Textiles: https://bit.ly/2RaeagW

Source: IBMF

Babu T K

Founder & CEO of Elmeasure India Pvt. Ltd., Mr. Babu is an innovator & practitioner of energy saving products & solutions. He is obsessed with the idea of making the world a better place in the area where the impact is huge & faster i.e., Energy.

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