a.t.e. enterprises private limited
TRANSCRIPT
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A.T.E. ENTERPRISES PRIVATE LIMITEDSince 1939
v1.4 – updated 1st Jan ‘16
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Retrofits and Accessories
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Retrofits and Accessories
SavesCost
ImprovesProductivity
ImprovesQuality
Importance
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Problems of Indian Processing Units
Productivity
Quality
High cost of capital
Rising energy costs
Water scarcity
Critical
challenges
faced by Indian
processing
units
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Retrofits and utilities from A.T.E.
A.T.E. brings to you a range of retrofits and utilities that will result in:
Enormous
saving in
energy
Improved
productivity
Improved
quality
At a
substantially
low investment
With fastest
ROI!
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Mahlo Atmoset - SMT-12
• Online moisture control and
monitoring system
• Controls the steam input in drying
cylinders by optimising the drying
process and saving heat energy
• 30%-50% savings in steam
• Consistent quality output.
Payback in just 8 months!!!
References: Alok Industries Ltd (Vapi), Auro Textiles (Baddi), Welspun (Anjar), GHCL (Bhilad)
Save e
nerg
y –
Sa
ve c
ost
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
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*N.B: Performance depends on constancy of input parameters and maintenance
Payback in just 2 months!!!
References: Vaibhav Processing (Erode), Kongoor Textile Process (Tirupur)
• 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 @ 80˚C
cooled to 41.15˚C
Fresh water @ 25˚C; heated up
to 63.57˚C
Thermal efficiency: 886.1kW
Fuel used: Firewood (calorific value of 3000kcal/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*
Save e
nerg
y –
Sa
ve c
ost
Luwa - Water To Water Heat Recovery System
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Payback in just 15 months!!!
References: Ruby Mills (Khopoli), Oswal F.M. Hammerle Textiles Ltd (Kolhapur), GHCL (Bhilad)
• A retrofit for the Osthoff singeing
machine for objective measurement
of the hairiness of the fabric
• 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.
W/o online
hairiness
tester
With online
hairiness
tester
Consumption of gas 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
roved
qu
ality
& c
ost
savin
gs
Osthoff - Online Hairiness Tester
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References: Arvind Mills (Santej), Auro Textiles (Baddi), Alok Industries (Vapi)
• A robust, retrofit, made of metal
foam for the pre-dryer installed on
the CDR
• Reduces 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 –
Sa
ve c
ost
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
Payback in 50.4 months!!
Monforts - Infrared Pre-dryer for CDR
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Retrofits&
Accessories
SaveCost
ImproveProductivity
ImproveQuality
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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 Industries (Vapi), OswalHammerle(Kolhapur), Vardhman Fabrics (Bhopal), AuroTextiles (Baddi), Birla Century (Bharuch)
Mahlo Textometer RMS can be used in stenter, pad steam and pad
dry, CBR, Sanforizer
Mahlo - Textometer RMS
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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 Industries (Vapi), Oswal Hammerle(Kolhapur), VardhmanFabrics (Bhopal), AuroTextiles (Baddi), Birla Century (Bharuch), Jakharia Fabrics (Boisar) etc.
Imp
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CEIA metal detectors can be used in Shearing, Calendar, Shrinking
Singeing machines, Dye Padder and CBR
CEIA - Metal Detector (bar) – TE/SLD
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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)
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CEIA metal detectors can be used in a multitude of textile-related
applications
CEIA - Metal Detector (conveyor type) – THS 21
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Description
Comprising of EcomatAML, 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 Indusries (Vapi), Oswal Hammerle(Kolhapur), VardhmanFabrics (Bhopal), AuroTextiles (Baddi), Birla Century (Bharuch)
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Mahlo Ecopac EMC-15 can be used in stenters, dryers, sanforizer
Mahlo - Ecopac EMC-15
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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 Glass Works (Boisar), Sutlej Industries (Bhilad)
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Advance Cooling – Compressed Air Dryer
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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 Industries (Vapi), Ruby Mills (Khopoli), BRFL (Boisar), Kothari Exports (Kolkata), etc.
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Advance Cooling - Panel Air Conditioner
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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 Mills (Khopoli), Auro Textile (Baddi), Raymond UCO (Yavatmal)
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Advance Cooling - Water & Oil Chiller
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Retrofits&
Accessories
SaveCost
ImproveProductivity
ImproveQuality
SaveCost
ImproveProductivity
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Beating & Brushing systems
Benefits
Improved productivity
Improves quality
Energy optimisation
References
Alok Indusries (Vapi), Oswal F.M. Hammerle (Kolhapur), Vardhman Fabrics (Bhopal), Auro Textiles (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
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A.T.E. - Rotary Drum Filter
Benefits
Improved productivity
Improves quality
Reduce maintenance
References
Alok Industries (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 drum
without using water
Used in singeing/desizing
systems, CBRs, and CRP (Caustic
Recovery Plant)
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A.T.E. - Screen Filter
Benefits
Reduce labour cost
Less maintenance
Hassle free system
References
Chenab Textile (Kathua)
Mandhana (Boisar)
Description
A compact unit with spring type
brushing system for removal and
collection of fluff
Used in ETP inlet at preliminary
treatment stage and various
drainage outlet as well.
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Rotovac - Online Dust & Lint Removal System
Benefits
Reduce labour cost
Less maintenance
Hassle free system
References
Arvind Mills (Santej), NSL Textiles (Hyderabad), BRFL (Boisar), Wintry (Dombivali)
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
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Chamber extension for stenter and pad dry
Benefits
Improved productivity at low investment
References
India Dyeing (Erode), Alok Industries
(Vapi), BJ Textiles, Naidupet
Description
Additional chamber with running
stenter
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Montimac – Fabric preparation for digital printing
Benefits
Helps to reduce damage of heads by
fringe
Possibility to print ALL the REAL fabric
width without margin or wastage of
fabric
Improvement of the speed in the
preparation process to digital printing
References
Shrijee Lifestyle (Dombivali), D’Décor
(Boisar), Zenith (Surat)
Description
Automatic machine for high
precision trimming of fringes/threads
to make fabric suitable for digital
printing.
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Corino – Guidance System/Inlet 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
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Monforts – Eco Applicator
Benefits
Improves fabric quality by controlled
application
Reduces energy costs for drying /
increases speed
Reduce wastage of chemicals
References
Arvind Mills (Ahmedabad)
Description
For controlled application of
chemicals (softener, hydrophobic,
hydrophilic, stain repellants, etc..)
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Dunline - Endless Rubber Shrinking Belts
Benefits
Uniform performance throughout the
life of the belt
No material defect
Improves fabric quality
References
Alok Industries (Vapi), Raymond
(Kolhapur), Arvind (Naroda & Santej),
JCT (Pagoda) etc…
Description
For fabric pre shrinking on sanforizing
ranges
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Endless Felts
Benefits
Manufactured to offer uniform
performance throughout the life of the
felt; no material defects
Improves fabric quality
References
Jindal Worldwide (Ahmedabad), Bhaskar
Denim (Bhopal), Welspun (Anjar), NSL
(Guntur)
Description
For drying & giving handle to fabric
used on palmer drum of sanforizer,
relax dryer, printing dryer
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Dunline - Accessories
Benefits
Maintain and assist longevity of the
belt & felt
References
BRFL (Tarapur), Mandhana (Tarapur)
Nahar (Lalru), Oswal Denim (Bhopal), Bhaskar (Bhopal)
Description
Belt Safe Compound
Safe wash
Belt Lube
Parallel Gauge
Surface Contact Thermometer
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MAG – Textile Testing Instruments
Benefits
Quality Assurance
Support customization
Calibration & test certification
Provision of AMC and OMC
References
E I Dupont India(Hyderabad), Alok Industries
(Silvassa), Morajee (Maharashtra), Alps
Industries (Ghaziabad), Grasim (Bhiwani),
Shree Sidvinayak Texco (Ludhiana), Shree
Balaji (Ludhiana), Partap Industries
(Punjab), Ahuja Cotspin (Punjab), Garg
Acrylics (Punjab), KPR Mill (Tamil Nadu),
Keshar Multi Yarns (Kolkata), Vishnu Cotton
Mills (Kolkata), Autotech (Surat)
Description
High quality textile testing instruments at
affordable price
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Valence – Static Eliminators
Benefits
Improves safety
Helps to improve productivity
Helps to improve quality
References
Nahar (Lalru), Tex n Nets (Gurgaon), Jain
Texties (Gurgaon), Surya Processors
(Ghaziabad), Alps Industries (Ghaziabad),
Kudu Knits (Ludhiana)
Description
Compact, sturdy and reliable static
discharge bars to eliminate electrostatic
charge on moving parts. CE certified
product.
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Material Handling Systems
Benefits
Low effort transport system
Suitable for heavy loads
Trouble free working
References
NSL (Guntur), Birla Century (Bharuch),
K G Denim (Mettupalayam), D Décor
(Tarapur), Premier Fine Linens
(Perundurai), Trident (Budhni) and
Himatsingka Linens (Hassan), Welspun
(Anjar)
Description
Supply of all types of material handling
equipment to store and move textile
substrate from one machine to another,
in the textile unit
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Specialty lubricants –
DuPont, Setral & Ultrachem
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 Dyeing, Alok Industries, BRFL, Valient Glass, Mudra Lifestyle, Ruby Mills, Arvind Mills, Premier Mills, HimatsingkaLinens, Vardhman etc…
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Softech Controls –
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), Welspun Syntex
(Silvassa), E Land (Boisar), Raymond,
Soktas (Kolhapur), Morarjee (Nagpur)
Description
Complete retrofit and automation
customized solutions for the textile
industry
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Liquid Transfer Pumps
Benefits
• effectively manage high water demands
• auto chemical dosing & monitoring
• non clogging reliable submersible pumps
• reduction in manpower & testing due to
automated system
References
Arvind (Ahmedabad), Morarjee
(Nagapur), SEL (Luidhana), Royal
Classic (Tirupur), Alok (Vapi)
Description
World class solution for water
distribution, waste water, dosing system,
hydro pneumatic booster systems for
the textile industry
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Beba - Foam Mixer/Generator
Benefits
• working range from 300-3500 kg/hr
• adjustable foam weights 100-1000 g/l
• product viscosity upto 25000 mPas
• automatic gas-air mixing
References
Description
World class solution for foam
technology for the textile, carpet, non-
woven and all other industries
Rotor stator system
Oscillating mixing
head
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B Tex – Inspection & Packing
Benefits
• Italian technology at affordable price
• No stretch in fabric
• Maintenance free
References
Description
Manufacture machines that can inspect, measure, auto cut / doff, and conveys the presentable fabric rolls to packing. Suitable for all types of fabrics including silks, elastic knits, heavy woven fabrics, technical fabrics. Inspection, Rolling, Folding, Fabric Preparation lines, Packing machines.
• Raymond, Monti, Soktas, Premier,
Himatsingka, Alok, D’Décor, G.M,
Indocount and many more…
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THANK YOU