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  Energy monitoring for the textile industry

Energy management system ‘EnergyMaster‘ for economic and ecological optimization of energy consumption and resources input.

The challenge in terms of sustainability:

Multiple production steps within the textile industry require a high energy and resource input. In many countries, rising energy costs and increasing governmental legislation imposes severe challenges on textile companies. Customers and governmental authorities demand proof about an optimal input of energy and resources. In some countries the proof of a positive energy balance is a crucial factor which determines the future expansion or even existence of the company.
By introducing an energy management system, targets and goals for the optimization of energy can be planned, implemented and monitored (PDCA-cycle). The results are documented by the energy management system. By linking the recorded energy data with the production data, conclusions can be made as to where further energy savings can be found.
As the energy consumption is very high in the textile finishing department, it is common practice to start here. Later, departments like spinning, weaving or knitting can be added.
Thus textile production becomes more ecological, economical and energy efficient.

The initial situation:

In the textile industry the production is mostly planned without knowing specific energy key data. Wastage of energy can be the result of many causes: Unfavorable machine loads, too many rinsing cycles, increased machines cleanings by suboptimal production planning, leakages in pipes, process temperatures are too high, activations during machine stand-stills, peak consumptions during high production phases, etc. All of which creates unnecessary high costs.

The solution:

All consumers are equipped with energy counters. The data is collected in a data base. Based on the principle of monitoring and planning the energy consumption (power, gas, pressurized air, water, steam, waste water, CO2 emissions) is collected and analyzed. For example: When the power consumption exceeds a critical value, a warning is given and managers can take action, e. g. by blocking additional consumers. This prevents peak current consumptions which can be charged at high costs by the energy provider.

By the structured approach of using an energy management system, companies can find out where Energy is wasted and can act accordingly. Cost savings in energy immediately reduce the basic company costs.

Above all, production data of an MES-system can be linked with the energy data. Energy costs per batch, article or order can be calculated and for each batch, the most economic and ecologic machine can be selected. By introducing an energy management system, an ongoing process to improve energy efficiency begins and energy awareness becomes part of the company culture.

The sustainable strengths:

  • Lowering CO2 Emission (carbon footprint)
  • By using EnergyMaster in finishing, up to 25% of energy costs can be saved.
  • Dependency on energy costs falls.
  • Savings result in a profit increase
  • Reports for customers and ISO standards (ISO50001)
  • Automatic warnings of exceptional consumptions.
  • Energy costs can be calculated per batch/article/order…

The inventors:

In close cooperation with reputable customers the EnergyMaster software package was written by our development team, according to the requirements of the textile industry.

Brief profile of the company:

Name: Sedo Treepoint GmbH
Headquarters: Mengerskirchen
Year established: 1978
Employees: 40
Solutions:

  • Controllers, PLC's, I/O ´modules and sensors for machine automation
  • Software for central production planning and supervision
  • Data acquisition
  • Recipe and color management software for laboratory and production
  • Quality control systems for laboratory and production

Internationality: Branch offices in Switzerland, Belgium, China, India, Italy, Singapore, USA, world-wide network with distributors and agencies.