Energy Consumption

Erdem Ko,
Emel Kaplan
ukurova University,
Textile Engineering Department,
Adana, Turkiye
E-mail: [email protected]
An Investigation on Energy Consumption

in Yarn Production with Special Reference
to Ring Spinning
Abstract
The aim of this study was to evaluate the energy consumption, in general, for ring type yarn
manufacturing systems and to examine the energy consumption in a chosen spinning mill
by considering the available data including installed power, monthly and yearly energy
usage. A simple theoretical approach for predicting the specific energy consumption in a
particular yarn type produced in chosen spinning mill was developed. The results obtained
by applying this model to a specific yarn was compared with the relevant values available
in the literature.
Key words: energy consumption, yarn manufacturing, ring spinning, textile.
n Introduction
Yarn manufacturing
Yarn can be defined as a thin elongated
structure in which fibers hold each other
by the effect of friction or twist. If the
yarn is produced from staple fibers it is
called spun yarn, otherwise it is known as
continuous filament yarn. The formation
of spun yarn comes true when the basic
manufacturing processes such as opening, cleaning, blending, carding, drafting
and spinning are performed. In some
systems, combing and roving processes
are added to these steps. The properties
and structure of yarn change not only according to the production steps but also
the spinning system used for manufacturing. The system used for yarn formation
depends on such factors as fibres to be
used, properties of yarn to be produced
and economic implications. The spinning
systems can be classified as conventional
and unconventional . The ring spinning
system can be considered as conventional (traditional) system whereas open-end,
wrap, air-jet and self-twist spinning systems are unconventional (nontraditional)
systems. In all these systems, twisting
and winding the yarn on the package
is formed by applying different mechanisms. Although studies and developments about new spinning systems go
on, the ring and open-end rotor spinning
systems are the most widespread system
for yarn manufacturing [1 - 6].
The ring spinning system is the oldest
spinning system that remains dominant because of the high quality yarns
it produces. Ring spinning has various
advantages besides disadvantages. This
system allows various types and lengths
of fibres (natural, man-made) to spin on
a wide count range from 6 tex to 118 tex
18
whereas this range is between 17 and

118 tex in rotor spinning. By combing
option, the high quality combed yarns
which are smoother, brighter and more
compact can be produced using the
ring system. On the other hand, the ring
spinning system has two main problems.
The first is low production speed because
of frictional contact of ring and traveller, and the yarn tension caused, and the
second is high energy consumption that
causes high production costs [2 - 6].
er, labour, capital etc. The cost of yarn

excluding raw material is termed manufacturing cost. The share of the factors in
manufacturing cost changes according to
the yarn properties, machine operational
properties and economical situation of
the spinning mill [3, 7].
Table 1 illustrates general shares of cost
factors for 20 tex combed cotton yarn the
among the chosen countries. Raw material (fibre) forms nearly half of the yarns
total cost and other cost factors such as
labor, energy, capital cost of machines,
auxiliary material cost and waste make
up the remaining part. After raw material,
capital and energy costs have the highest
proportions in the total . The power or
energy cost takes 9% share of the specific
yarn total cost in Turkey. This share increases to 17% if the raw material cost is
excluded. Since the unit price of energy
and labor change independently from
spinning mill conditions, reducing these
costs depends on minimising energy usage and labor wages.
Manufacturing cost of yarn

In todays competitive conditions, competing with other manufacturers depends
on producing high quality yarns with
reasonable costs. Nowadays, the free
market determines the price of products
irrespective of the administration of
spinning mills. For this reason gaining
more profit depends on minimising the
manufacturing cost of yarns. Especially,
cheaper yarns that are produced by Far
East countries such as China, Indonesia,
draw the attention of consumers. This
affects other countries yarn manufacturers negatively and subjects such as
cost calculation and cost minimisation
become primarily important [7].
Since twisting is accomplished by the

rotation of the spindle and bobbin, the
energy consumption of ring spinning is
higher than the other spinning systems. In
the ring spinning system, energy is used
for feeding the roving to the machine,
The cost of yarn consists of several factors such as raw material , energy or pow-
Table 1. Manufacturing cost factors for the chosen countries [8].

Countries
Manufacturing Cost Factors For Chosen Countries (2003), %

Brazil
China
India
Italy
Korea
Turkey
USA
Raw material
50
61
51
40
53
49
44
Waste
11
Labor
24
19
Energy
12
10
Auxiliary material
Capital
32
14
23
17
21
26
21
100
100
100
100
100
100
100
Total
FIBRES & TEXTILES in Eastern Europe October / December 2007, Vol. 15, No. 4 (63)
drafting and rotation of the spindle. At

least, 85% of the total power requirement
of a ring frame is consumed in driving
the spindles, depending on details such
as yarn count, package size and spindle
speed and the remainder is consumed by
drafting and lifter mechanisms [6].
Various studies have been done to determine the energy cost and consumption
of the ring spinning system [2, 3]. International Textile Manufacturer Federation
[8] has done the comparison of manufacturing costs of textile processes covering
spinning, texturing, weaving and knitting
in their yearly technical report. This report includes calculated costs for specific
ring and open-end rotor spun yarn among
the chosen countries.
The cost factors affecting ring and openend rotor yarn total cost were investigated by Kuuolu [9]. The labor and
energy cost of a chosen spinning mill was
examined and costs of different types of
yarns with changing machine parameters
were evaluated by Ko and Kuuolu
[10, 11]. rtlek et al. [12], compared the
calculated cost of 20 tex ring, open-end
and Vortex (MVS) yarns were compared
with each other. It was found that the
energy cost of 1 kg of ring yarn is the
highest of the three. Kaplan [7] studied
the cost factors which make up the total
product cost for the textile industry including spinning, weaving and finishing
and the product cost of chosen ring yarn
by using empirical formulas, taking into
regard specific operating conditions and
selected machine parameters .
Energy is necessary for each step of spinning processes to drive machines, air
conditioning and lighting, but the highest energy consumption occurs during the spinning process in spinning
machines [13]. Another study which
handled energy conservation in the textile industry focused on the electricity
consumption of each step of ring spinning for the modern and traditional factory [13]. Tarakolu [14] showed that
electrical energy consumption of 1 kg of
yarn changes between 2.7 kWh/kg and
4 kWh/kg. Additionally, it was pointed out
that thermal energy alternating between
1.1 MJ/kg and 4.7 MJ/kg is necessary for
processes such as fixation besides electrical energy needs. General assessment for
energy consumption and conservation in
fiber-producing and textile industries was
done by Kim et al. [15] while determining the power requirement of a specific
ring and open-end spinning machine with

chosen machine parameters.
Since the highest power is required
in spinning machines, many studies
have been carried out to determine the
power demand of spinning machines.
Krause and Soliman [16] attempted to
find a general formula for calculating
power/energy consumption per 1 kg yarn
in ring and open-end rotor machines. It
was found that in the coarse yarn range
(tex>60) the open-end rotor machine
needed less energy per kg of yarn than
the ring frame for warp yarns, for finer
yarns (tex<30), on the other hand, the
oe-rotor machine demanded more energy
per kg of yarn than ring frame. It was
reported that the factors affecting the
power demand of the ring system were
ring diameter, balloon height, spindle
speed and traveller mass [6].
A specific formula was developed to
determine the power consumption of
bare spindle (without bobbin) by Ye [17].
It was shown that oil resistance, upper
bearing system and friction between
footstep bearing and spindle blade tip
cause the power consumption of the
spindle driving unit in the ring spinning
system. A Detailed study was done by
Tang et al. [18, 19] in order to determine
the distribution of power requirements
during yarn winding in ring spinning.
A general equation for determining the
power requirement of ayarn winding system was established by using parameters
such as winding on time, yarn count,
mass of the yarn winding package. Tang
et al. [20] also established a model based
on an analysis of power distribution for
predicting the ratio of energy consumption to yarn-production for a full package
during yarn winding in ring spinning.
Chang et al theoretically and experimentally investigated the effect of yarn
hairiness on energy consumption and
found that the more hairiness the yarn
has the higher the energy consumption

during winding in the ring spinning system [21].
In this study, general information about
the energy consumption of spinning mills
is given and that of the chosen spinning
mill was analyzed by using data including installed power, as well as monthly
and yearly energy usage. In addition to
this, a simple approach for calculating
the specific energy consumption of specific yarn was developed. The calculation of specific energy consumption of
particular yarn produced in the chosen
spinning mill was done using the formulas recommended and the results obtained were compared with the relevant
values given in the literature.
n Energy consumption in yarn

manufacturing
General energy usage in ring spinning
Energy is generally used for operating
machines, air conditioning and illuminating the atmosphere where yarns
are manufactured in spinning mills. In
addition to these, compressors which
provide compressed air to the spinning
line use energy. Two types of energy
can be used in a specific spinning mill;
electrical energy and thermal energy.
Machines, air conditioning, lamps used
for illumination and compressors consume electrical energy while the thermal
energy is consumed by air conditioning
and processes such as fixation of yarns.
Generally thermal energy is obtained
from coal, diesel oil, fuel oil, natural gas
and steam [7, 22].
Table 2 shows the energy consumption
of a specific combed yarn in a modern
factory with its production steps. It can
be seen from the table that 221.1kWh
energy is used for a given spinning line
Table 2. Energy consumption of specific combed ring yarn [13].

Production Steps
Electricity consumption of specific combed yarn

per 1000 spindles for each process
kWh/1000 spindles
Share, %
Blowing Room
16.7
7.5
Carding
17.7
Combing
10.9
Drawing-Roving
Ring Spinning
Yarn Finishing Treatments
SUB TOTAL
Air Conditioning
TOTAL
9.1
66.1
30
14.7
6.5
135.2
61
85.9
39
221.1
100
19
of 1000 spindles, 61% of which is consumed by machines and the highest energy consumption with 30% share occurs
at the spinning stage.
The energy usage and energy cost of both
20 tex combed ring-spun yarn and 20 tex
open-end yarn for the chosen countries
are illustrated in Table 3. The amount
of energy needed for ring yarn changes
between 3.49 - 3.62 kWh/kg while the
energy needed for open-end yarn is
between 2.44 and 2.58 kWh/kg. Since
the electrical energy prices are different
in the chosen countries, the energy cost
differs from country to country although
the consumption is nearly the same.
Energy consumption of chosen
spinning mill
In order to obtain the necessary information about energy consumption of a
specific spinning mill, one which is able
to spin every kind of staple fibre (i.e. cotton, linen, polyester, viscone) in a wide
count range using both ring and openend systems was chosen. This spinning
mill included not only machines used
for manufacturing (blowing room, carding, combing, drawing, roving, spinning,
winding), but also included 5 air conditioning systems, 2 compressors and 2555
lamps for illumination. Besides this, the
chosen spinning mill used only electrical
energy.
The unit power needed for corresponding machines in production line and
power for the air conditioning system,
compressors and lamps can be seen in
Table 4. Installed power is a power needed for the each equipment if there is no energy loss; the actual power was calculated
taking into consideration energy loss or
energy efficiency. The total installed and
actual power needed for each equipment
given in the table was obtained by multiplying the number of machines with
unit power required. The subtotal of each
equipment group is also shown, i.e. subtotal of actual power necessary for carding machines is 229.5 kW. In addition,
the last column of the table shows the
share of actual power required for each
equipment group in the total actual power
consumption, i.e. carding machines form
9.44% of the total actual power consumption. The amount of total actual power in
the chosen spinning mill was determined
as 2432.8 kW in which machines, air
conditioning, compressors and illumination were included and the machines con-
20
Table 3. Energy usage for specific ring and open-end yarn [8].
Countries
Ring yarn (Combed)
Electrical
energy prices,
$/kWh
Open-End Yarn
Energy
consumption,
kWh/kg
Energy cost,
$/kg
Energy
consumption,
kWh/kg
Energy cost,
$/kg
China
0.066
3.49
0.23
2.58
0.17
India
0.084
3.57
0.30
2.50
0.21
Turkey
0.070
3.57
0.25
2.57
0.18
Brazil
0.031
3.54
0.11
2.58
0.08
S. Korean
0.047
3.62
0.17
2.55
0.12
USA
0.045
3.56
0.16
2.44
0.11
Italy
0.105
3.52
0.37
2.57
0.27
Table 4. Unit power consumption for chosen spinning mill.

For unit machine
For total
Number of
machines
Installed
power,
kW
Actual
power,
kW
Installed
power,
kW
Actual
power,
kW
Blow Room
(Cot-Linen Line)
36.00
22.00
36.00
22.00
Blow Room
(Automatic)
64.00
42.00
64.00
42.00
Blow Room (Manuel1)
16.30
8.00
97,75
48.00
Blow Room (Manuel2)
7.15
4.00
21,45
12.00
Blow Room
(Poly/vis)
26.10
10.75
104,50
43.00
Vertical Opener
9.40
6.00
47.00
30.00
SUB TOTAL
158.95
92.75
370,70
197.00
Carding M.
(Sacolowell)
4.00
3.30
20.00
16.50
Carding M.(C10)
13.25
8.50
106.00
68.00
Carding M.(Rieter)
10
20.70
14.50
207.00
145.00
Equipment Type
SUB TOTAL
Share of
each in
total actual
power, %
8.10
9.44
37.95
26.30
333.00
229.50
Drawing Machines
14
10.00
7.50
140.00
105.00
4.30
Combing Machines
6.53
5.50
26.12
22.00
0.90
Lap Machine
13.00
11.00
13.00
11.00
0.45
Roving Machines
12
17.30
11.40
207.50
136.80
5.60
Ring Spinning
Machines
33
40.00
34.00
1320.00
700.00
28.80
Ring Traveler Robots
10
0.497
0.30
4.97
3.00
0.10
Open-end Spinning
Machines1
81.60
60.00
408.00
300.00
Open-end Spinning
Machines2
100.00
67.50
100.00
67.50
Winding Machine
10
15.50
13.50
15.10
SUB TOTAL OF MACHINES
155.00
135.00
5.60
3078.29
1906.80
78.40
Compressor 1
58.00
40.00
58.00
40.00
Compressor2
45.00
24.00
45.00
24.00
103.00
64.00
103.00
64.00
SUB TOTAL OF COMPRESSORS

Air Conditioning
System1
110.00
55.00
110.00
55.00
Air Conditioning
System 2
147.10
91.00
147.10
91.00
Air Conditioning
System 3
147.10
116.00
147.10
116.00
Air Conditioning
System 4
126.00
73.00
126.00
73.00
Air Conditioning
System 5
81.50
55.00
81.50
55.00
611.70
390.00
611.70
390.00
0.04
SUB TOTALOF AR CONDITIONING

LAMPS
TOTAL
2555
2.63
16.00
102.00
72.00
2.98
3894.99
2432.80
100
sumed energy which formed 78% of the

total energy consumption alone.
The chosen spinning mill operated in
3 shifts a day which consisted of 8 hours
and also works 25 days a month. Considering the monthly operating time and
number of machines, the monthly (May)
energy consumption of the chosen spinning mill was calculated and all the data
are shown in Table 5. The actual total
monthly energy consumption of the spinning mill was 1459680 kWh/month in
May as shown. 78.4% of this energy
was consumed by the machines, see Figure 1.a and 37% of the monthly energy
consumed by the machines was due to
the ring spinning machines (Figure 1.b).
In order to determine the unit energy
consumption of unit yarn mass which
is known as specific energy consumption, the monthly energy consumption
of the investigated mill were divided
by monthly production quantity and the
variation obtained is demonstrated in
Figure 2. The amount of specific energy
consumption changed between 3.23 and
3.76 kWh/kg in the chosen mill among
the selected months. These values were
the average which changed depending
on the yarn properties.
Table 5. Energy consumption for chosen spinning mill in May.

Equipment Type
The amount of raw material R1 (kg)

which will be processed in the first
machine (bale opener) can be found by
using the total waste ratio WTot (%) and
mass of the specific yarn, M (kg) as
R1 = M (1 + WTot)
(1)
Operating time for the first machine, t1

(hour), can be determined as follows,
t1 = R1/(L11n1)
(2)
Daily energy
consumption, kWh
Monthly energy
consumption, kWh
Blow Room (Cot-Linen Line)
22
528.0
13200
Blow Room (Automatic)
42
1008.0
25200
Blow Room (Manuel1)
48
1152.0
28800
Blow Room (Manuel2)
12
288.0
7200
Blow Room (Poly/vis)
43
1032.0
25800
Vertical Opener
30
720.0
18000
SUB TOTAL
197
4728.0
118200
Carding M. (Sacolowell)
16.5
396.0
9900
68
1632.0
40800
Carding M.(C10)
Carding M.(Rieter)
145
3480.0
87000
229.5
5508.0
137700
Drawing Machines
105
2520.0
63000
Combing + Lap Machines
33
792.0
19800
136.8
3283.2
82080
703
16872.0
421800
220500
SUB TOTAL
Roving Machines
Ring Spinning Machines + Robots
Open-end Spinning Machines
367.5
8820.0
Winding Machines
135
3240.0
81000
MACHNE TOTAL
1906.8
45763.2
1144080
AIR CONDITIONING SYTEMS
390
9360.0
234000
ILLUMINATION
72
1728.0
43200
COMPRESSORS
64
1536.0
38400
2432.8
58387.2
1459680
TOTAL
Determination of energy consumption

for chosen yarn
In order to obtain the specific energy consumption of any yarn, a simple approach
was developed. Since a manufacturing
line contains many steps/machines, the
approach is explained here for the first
machine which is outlined as the bale
opener and the approach should be repeated for the rest of the machine/step.
According to this approach, raw material used for each machine should be first
found and then the operating time of each
machine obtained. Using the operating
time and actual power of manufacturing machines, the energy consumption
of each machine during manufacturing
could easily be calculated [7].
Hourly energy
consumption, kWh
a)
b)
Figure 1. Percent distribution of energy consumption in examined spinning mill; a) percent

distribution of total energy, b) percent distribution of energy used for machines.
Figure 2. Specific monthly energy consumption for spinning mill.

where; L1 (kg/h) is the manufacturing
rate of the machine, n1 is the number
of machines used and 1 (%) is the mechanical efficiency of this machine. With
given parameters, the electrical energy,
E1 (kWh), used for the first machine can
be obtained by
E1 = t1 N1 E1 n1
(3)
Here, N1 (kW) is the installed power of

the first machine E1 (%) is the energy
efficiency concerned. After calculating
the energy consumption of each step, the
total energy consumed for operating the
21
machines, EM (kWh), can easily be calculated by the following equation.
EC = EC M / G
where, EC expresses the total energy

consumption of the air conditioning system in one month while G is the monthly
yarn production in kg. Similarly, the
energy consumption for illumination, Eil
(kWh) is found as
Eil = Eil M / G
(8)
Here; Eil is the total monthly energy usage of lamps needed for illumination.
(4)
where Ei is the energy consumption of
blow room (E1; energy for bale opener,
E2; energy for cleaner, E3; energy for
mixer etc.), ECa is the energy consumption of carding, ED is the energy
consumption of drawing, ECo is the energy consumption of combing, ER is the
energy consumption of roving, ES is the
energy consumption of spinning, EW
is the energy consumption of winding
step, i represents the relevant individual
machine and n is the total number of machines in the blow room.
Consequently; the total energy consumption for any specific yarn can be calculated by summing up the relevant energy
consumption equations given above as
ETot = EM + ETA + EC + Eil (9)
Prediction of Energy Consumption
The energy consumption for 20 tex
(Ne 30) combed ring yarn produced in
the spinning mill under investigation
was calculated by applying the procedure given above. Here; 3000 kg, 20 tex
combed yarn is supposed to be produced
in the ring spinning system at a speed of
17500 rev/min and with a twist factor
(tex) of 3828.
Energy consumption of compressors for

the first machine, EA1 is found as
EA1 = t1 NA C1 n1
(7)
(5)
where C1 (m3/h) is the compressed air

needed per hour, NA (kWh/m3) is the unit
power for compressors which can be determined by dividing the installed power
of the compressor by the compressed air
capacity. Total energy consumption for
providing compressed air in general,
Energy consumption for machines and

compressed air
The results obtained by the procedure
outlined above are demonstrated in
Table 6. This contains production parameters (type and number of machines,
actual production rate, actual installed
power etc.) and calculated data (operating
time, energy use for operating machines
and compressed air). For the investigated
spinning mill, the unit power needed for
compressors to provide unit compressed
air (NA) was determined as 0.12 kWh/m3.
ETA (kWh), is found as

and here again j represents the relevant
machine and m is the total number of
machines that need compressed air in the
production line of specific yarn.
Energy used for air conditioning during
yarn production EC is
Table 6. Energy consumption of chosen yarn.
Production parameters
Machines
No of
mach.
Calculated data
Actual
Actual Unit comp. Operat.
production
unit
needed time (t),
rate (l),
power (n), air
(c), m3/h
h
Kg/h mac.
kW
Energy
for
machines (e),
kWh
Energy
for
compr. air
(ea), kWh
Uniflock
950
6.00
4.02
24.12
Uniclean
950
6.75
4.00
27.00
Unimix
617.5
5.25
6.10
32.03
Uniflex
570
9.00
6.60
59.40
Kondenser
570
4.00
6.50
26.00
Carding M.
42.0
14.50
9.10
22.40
1299.20
97.80
Drawing M.
181.6
7.50
0.48
20.23
151.73
1.17
Unilap
381.5
11.00
3.30
9.60
105.60
3.80
Combing M
47.0
5.50
2.40
25.62
422.73
22.10
Drawing M.
109.0
8.25
0.56
28.80
237.60
2.00
Roving M.
116.6
11.40
0.40
26.73
305.00
1.30
Ring Spin.
26.5
34.00
36.25
38.73
3950.50
505.40
Winding M.
84.7
13.50
30.00
35.60
480.60
124.60
7121.50
769.47
TOTAL
22
14.45
11.30
Figure 3. The share of energy used for

machines (%).
As the machines in the blowing room

were interconnected, the compressed air
needed has been calculated cumulatively
by taking the operating time as 6.6 hours.
Using the parameters in the table and
related equations, the total energy consumed for machines was found to be
7121.5 kWh and 3950.5 kWh of this was
used by the ring spinning machines.
In order to see the percentage of the
energy used for each machine, Figure 3
was obtained. As can be seen, the maximum energy consumption (3950.5 kWh)
among machines occurred in ring spinning machines (55.5%) and carding machines follow this with a share of 18.2%.
This figure also provides the opportunity
for comparing the corresponding data
with the data available in [23] as shown
in Table 7. The calculated share of each
machine type in total energy consumption was compared with the results of
10 tex. As the 10 tex yarn is finer than
20 tex, the share of the ring machines for
10 tex yarn seemed to be higher than that
of 20 tex, as expected.
Since similar data showing the shares
of machines in total energy consumption
has not been reached for 20 tex yarn in
literature, the energy consumption for
10tex yarn was also calculated by using the present approach with suitable
production parameters for 10 tex yarn
(tex = 3828, 16000rpm) and the results
were compared with the data in literature
[23], as shown in Table 8. The results
calculated and data given in literature
are nearly the same. The small differences occurring between the values are
attributed to the exclusion of the winding
step for data in literature and the changes
faced in production parameters.
Total energy consumption including air
conditioning and illuminating
So as to calculate the total energy usage
for the chosen yarn, energy consumption of air conditioning and illuminating
should be found, as explained before.
For this reason, data such as monthly
energy consumption for air conditioning

and illuminating system and the amount
of monthly yarn production should be
obtained. Monthly energy consumption
for air conditioning and illuminating
were calculated as 234000 kWh/month
and 43200 kWh/month respectively, as
given in Table 5. And also; it was determined from the mill records that total
yarn production was 401580 kg/month
for the examined month (May). By application of the developed approach, energy
consumption for air conditioning and
illumination were found and the results
are shown in Table 9.
Specific energy consumption for the
yarn concerned was determined as
3.32 kWh/kg which can also be seen
from the table. Specific energy consumption for 20 tex combed ring yarn changes
between 3.49 and 3.62 kWh/kg among
the chosen countries (see Table 3). The
data obtained from the present study
(3.32 kWh/kg) represents a relatively
smaller value than that of the selected
countries. It is thought that the difference between the values comes from the
changes in manufacturing parameters of
machines such as type, waste ratio, speed
and energy efficiency.
Energy consumption for different type
of yarns
The amount of energy consumption for
different types and counts of yarn was
calculated in the same way and the results obtained are shown in Table 10.
The finer yarn needs more energy consumption for all types of yarn. Yarns
used for weaving involve more twist than
yarns used for knitting and production
speed is low for weaving yarn and as a
result, with the same count more energy
is consumed for weaving yarn. Also, for
the same count, the energy consumption
for combed yarn is higher because of the
additional production step (combing).
Specific energy consumption of 20 tex
combed weaving yarn is recorded as
3.64 kWh/kg whereas; the calculated
consumption in the present study takes
the value of 3.32 kWh/kg for the same
yarn. It appears that the differences in
manufacturing parameters cause this
discrepancy.
Energy consumption for ring spinning
machine
Since the highest energy consumption
occurs in spinning machines during yarn
manufacturing, many studies have been
Table 7. Comparison of energy consumption.

The Share of Energy Consupmtion for Each Machine (%)
Machines
10tex (Literature)[23]
20tex (Present Approach)
3.37
6.52
3.52
2.09
5.77
78.73
-
2.4
18.2
7.4
5.5
4.3
55.4
6.8
100
100
Blowing Room
Carding
Combing
Drawing
Roving
Ring Spinning
Winding
TOTAL
Table 8. Comparison of energy share of machines for 10tex yarn.

Production Parameters
Machines
No of
mach.
Uniflock
Uniclean
Unimix
Uniflex
Kondenser
Carding M.
Drawing M.
Unilap
Combing M
Drawing M.
Roving M.
1
1
1
1
1
4
1
1
3
1
1
Ring Spin.
Winding M.
Calculated Data for

10tex
Actual
Actual Operat.
production
unit
Time
rate (L),
power,
(t),
kg/h mac. (N), kW
hour
950.00
950.00
617.50
570.00
570.00
38.84
167.65
381.15
43.40
100.61
72.88
6.00
6.75
5.25
9.00
4.00
14.50
7.50
11.00
5.50
8.25
11.40
4.02
4.00
6.10
6.60
6.50
23.78
21.90
9.60
27.76
31.24
42.80
24.14
27.00
32.03
59.40
26.00
1378.95
164.25
105.60
458.15
257.73
487.92
8.56
34.00
39.95
1222.40
45.65
13.50
33.02
892.35
TOTAL
Calculated
energy
share for
machines,
%
Machines
Energy
for
machines
(E), kWh
Data in
literature for
10 tex,
% (23)
Blowing
Room
1.1
3.37
Carding
Combing
Drawing
Roving
Ring
Spinning
Winding
8.5
3.5
2.6
3.0
6.52
3.52
2.09
5.77
75.8
78.73
16139.90
TOTAL
5.5
100.0
100.00
Table 9. Total energy consumption for chosen yarn.

Consumption place
Machines
Compressors
Illumination
Air Conditioning
TOTAL
Energy
consumption, kWh
Share, %
7121.5
769.5
322.7
1748.0
71.3
7.7
3.5
17.5
9961.7
100.0
Specific energy
consumption, kWh/kg
Table 10. Specific energy consumption for chosen yarns [10].

Specific energy consumption for chosen yarns, kWh/kg
Yarn count, tex
37
33
30
25
20
17
15
12
Combed
Carded
Knitting
Weaving
Knitting
Weaving
1,38
1,58
1,79
2,19
3,06
3,89
4,42
5,52
1,63
1,88
2,12
2,60
3,64
4,62
5,25
6,81
1,34
1,54
1,73
2,11
2,96
3,74
4,23
5,52
1,62
1,86
2,09
2,55
3,57
4,53
5,12
6,72
carried out on the energy consumption

of spinning machines. One of the studies
shows that specific energy consumption
in a ring spinning machine, ER (kWh/kg),
can be calculated with the equation given
below [16].
ER = 106.7 F-1.482 Dr3.343
(10)
n0.917 text0.993
Here; F is the linear density of yarn

(tex), Dr is the diameter of ring (m),
n is the speed of spindle (1000 r.p.m.)
and text is the twist factor of the yarn.
The production parameters of 20 tex
combed yarn of which the total energy
consumption is calculated in the present
study are n = 17500 r.p.m., text = 3828
23
(e = 4) and Dr = 0.04 m. If these parameters are evaluated in the equation

(10), the specific energy consumption of
ring machines is found as 1.36 kWh/kg.
As can be seen from Table 8, the total
energy consumption of ring machines
during manufacturing was calculated as
3950.5 kWh with the present approach.
If the total consumption is divided by
production amount, the specific consumption is obtained as 1.32 kWh/kg
and this value seems to be 3% lower than
that obtained by the equation (10). The
difference between these two values is
attributed to the difference detected in
parameters such as speed, waste ratio,
mechanical efficiency and energy loss of
ring spinning machines.
n Summary
As a result of detailed investigations
into energy consumption for yarn manufacturing with special reference to ring
spinning, important findings are summarised below.
1. It was shown that the manufacturing machines consume 72% of the
total monthly energy consumption
(1459680 kWh/month) while air conditioning comprises 16% of the total
energy consumption in the chosen
spinning mill. Additionally, specific
energy consumed for each month in
a one-year period was calculated
and it was determined that the calculated values change between 3.23 and
3.76 kWh/kg.
2. With the simple model developed,
the total energy consumed during
the manufacturing of 100% cotton,
20 tex combed ring spun yarn in the
chosen spinning mill, was calculated
as 9961.7 kWh, 71.3% of which was
consumed by manufacturing machines. The highest energy consumption with 55.5% share occurred in
spinning machines alone. The values
calculated were compared with the
data available in the literature and
it was shown that there was a close
agreement between calculated data
and data given in literature. The small
differences were attributed to differences in operation parameters such as
type, mechanical efficiency, energy
loss and waste ratio of machines.
3. The specific energy consumption for
20 tex combed ring yarn was obtained
as 3.32 kWh/kg and this value was
compared with the values outlined by
24
ITMF (changing between 3.49 and

3.62 kWh/kg for the same yarn type).
The difference between calculated
and reported values is thought to be
because of the difference in production parameters.
4. The specific energy consumption of
the ring spinning machine during the
chosen yarn production, was calculated as 1.32 kWh/kg by the given
approach, while this value was obtained as 1.36 kWh/kg by the equation
given in literature. There seemed to be
3% percentage difference between the
calculated value and data taken from
literature.
5. It has been demonstrated that the approach given in this study can be used
to calculate the total and specific energy consumption of a particular type
yarn with reasonable confidence.
References
1. Kornreich E.; Introduction to Fibers and
Fabrics-Their Manufacture and Properties, Second Edition England: Seven
Corners Press; 1966.
2. Lawrence C. A.; Fundamentals of Spun
Yarn Technology, New York: CRC Press;
2003.
3. Lord P. R.; Hand Book of Yarn Production
Technology Science and Economics, The
Textile Institute, United Kingdom :Cambridge Woodhead Publishing; 2003.
4. Grosberg P., Iype C.; Yarn ProductionTheortical Aspects, United Kingdom: The
Textile Institute; 1999.
5. McCreight D. J., Feil R. W., Booterbaugh
J. H., Backe, E. E.; Short Staple Yarn
Manufacturing, North Carolina: Carolina
Academic Press; 1997.
6. Oxtoby E.; Spun Yarn Technology,
London: Butterworth & Co Publishers;
1987.
7. Kaplan E.; The Cost Factor in Textile Industry and General Utilization of Energy
Cost, MsC Thesis, Cukurova University,
Institute of Natural and Applied Science,
Textile Engineering Department, Adana
2004 (in Turkish).
8. ITMF, International Comparison of
Manufacturing Costs, Spinning/Weaving/
Knitting, Sweden: International Textile
Manufacturers Federation; 2003.
9. Kuuolu R.; Analysis of Turkish Textile And Clothing Sectors, MsC Thesis,
Cukurova University, Institute of Natural
and Applied Science, Textile Engineering
Department, Adana, 2002 (in Turkish).
10. Ko E, Kuuolu, R., Spinning Yarn
Production Costs in Open-End and Ring
Systems, Textile Technology, 2004; Number 100: pp. 122-134 (in Turkish).
11. Ko E., Kuuolu R., Factors that Affect

Labor and Energy Costs in Yarn Production-Ring Spun Yarn Production, Textile
Technology, No. 103 (2005) pp. 160-169
(in Turkish).
12. rtlek, H.G., ener, M., lk., ., Production Cost Analysis of MVS Yarns and
Comparison With the Conventional Spinning Systems, Textile Technology, 2004;
August: pp. 82-92 (in Turkish).
13. Anonymus; Output of a Seminar on
Energy Conservation in Textile Industry,
Malesia: 1992; www.unido.org/userfiles/
PuffK/textile.pdf.
14. Tarakolu I.; Energy Consumption and
Conservation of Textile Finishing Mills,
Bursa:Uludag University Press; 1984.
(in Turkish).
15. Kim S. Y., Grady P. L., Hersh S. P.; Energy Consumption and Conservation in the
Fibre-producing and Textile Industries,
The Textile Institute Vol. 13, No. 3, 1983.
16. Krause H. W., Soliman H. A.; Energy
Consumption of Rotor Type OE-Spinning
Machines as Compared to Ring Spinning
Frame. International Textile Bulletin,
1982; Third Quarter: pp. 285-303.
17. Ye G.; Calculation of Power Consumption of Bare Spindle (Without Bobbin) for
Ring Spindle. Journal of China Textile
University, English Edition, Vol. 13, No.
2 (1996) pp. 62-66.
18. Tang Z. X., Wang Z., Fraser B.; Distribution of Power Requirements During
Yarn Winding in Ring Spinning. Textile
Research Journal, Vol. 74 (2004) pp.
735-741.
19. Tang Z. X., Wang Z., Fraser B.; Energy
Consumption Per Unit Yarn Production in
Ring Spinning. Proceedings of the Sixth
Engineering Mathematics and Applications Conference, EMAC 2003 Proceedings, UTS Printing Services: 2003; pp.
289-294.
20. Tang, Z. X., Wang, Z. and Fraser, B.,
Minimizing Energy Consumption of Yarn
Winding Ring Spinning. Textile Research
Journal, Vol. 74 (2004) pp. 1097-1103.
21. Chang L., Tang Z. X., Wang X.; Effect of
yarn hairiness on energy consumption in
rotating a ring-spun yarn package. Textile
Research Journal Vol. 73 No. 11 (2003)
pp. 949-954.
22. DE, Energy Consumption in the Manufacturing Industry (Establishments with
500 Tons of Oil Equivalent or More Energy Consumption) 1999-2001, Ankara:
State Institute of Statistics Prime Ministry
Republic of Turkey, 2004; No. 2916.
23. Bozkurt Y., Energy Consumption and
Conservation in Conventional Yarn
Manufacturing, Seminar Notes about
Energy Consumption and Conservation
in Textile Mills, Bursa: Smerbank Textile
Education and Research Institute, 1985;
No. 77 (in Turkish).
Received 06.09.2006
Reviewed 30.10.2006
Since July 1st, 2007 according to the Decision of the Polish Minister of Economy of June 20th, 2007 (published in:
Journal of Laws of 2007, no.115, item 799)
n Institute of Textile Architecture (Instytut Architektury Tekstyliw IAT)
n Institute of Textile Materials Engineering (Instytut Inynierii Materiaw Wkienniczych)
n Tricotextil Institute of Knitting Techniques and Technologies (Instytut Technik i Technologii Dziewiarskich
Tricotextil)
have been almagamated with the Textile Research Institute (Instytut Wkiennictwa IW).
Pursuant to paragraph 6.1, point 3 of this Decision, Textile Research Institute enters into all the rights and obligations
which were the subject of the included institutions despite their legal characteristics.
Correspondence should be directed to the following address:
Textile Research Institute (IW), 5/15 Brzeziska street, 92-103 d, Poland.
Director: Mrs Jolanta Mamenas M.Sc., Eng.
Deputy Director for R&D: Mrs Jadwiga Sjka-Ledakowicz Ph.D., Eng.
The consolidated Institute combines traditions and experience of four institutions specialising in different areas of
textiles.
Currently, at our disposal we have considerable R&D potential:
n 128 research workers
n 10 accredited testing laboratories (testing and certification of textile materials)
n The Institute is a notified body within 3 EU Directives:
88/378/EEC/ The Directive on the Safety of Toys,
89/686/EEC/ The Directive on Personal Protective Equipment (PPE)
93/42/EEC/ The Directive on Medical Devices
n The Institute is the coordinator of 2 scientific networks:
n TEXMEDECO NET International Scientific Network Textiles and Health
n INTRANANOTEX Nanotechnologies in textile industry
Our Institute acting as a supporting partner for the textile industry has been carrying out R&D work in the areas of :
n material engineering,
n polymers,
n textile chemistry,
n biotechnology,
n environmental protection,
n textile techniques and technologies.
Strategic areas of R&D work of IW are the following:
n new materials and technologies
n environmental protection
n health protection
n new methods of assessing the properties of textile fabrics.
Trends in research directions illustrate the transformation of the European textile industry whose character is
continuously changing and is shifting from traditional textile production to:
n innovative goods - high-tech products of special properties and for new application fields
n functional textile products - barrier products - added value textiles, smart textiles,
n biomaterials.
An interdisciplinary approach is necessary to develop the technologies of producing such textile materials. We are
open to cooperation and welcome potential partners willing to search for new ideas in textiles.
Further information:
Instytut Wkiennictwa Textile Research Institute;
address: Brzeziska 5/15, 92-103 d, POLAND
Jadwiga Sjka-Ledakowicz Ph.D., Eng. tel. (+4842) 6163110,
Magorzata Cielak Ph.D., Eng. tel. (+4842) 2534405,
fax: (+4842) 6792638 ; e-mail: [email protected], [email protected], [email protected]
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What are the main advantages and disadvantages of ring spinning?

What are the main advantages and disadvantages of ring spinning?

What factors contribute to the manufacturing cost of yarn?

What factors contribute to the manufacturing cost of yarn?

Erdem Ko,

An Investigation on Energy Consumption

whereas this range is between 17 and

er, labour, capital etc. The cost of yarn

Manufacturing cost of yarn

Since twisting is accomplished by the

Table 1. Manufacturing cost factors for the chosen countries [8].

Manufacturing Cost Factors For Chosen Countries (2003), %

drafting and rotation of the spindle. At

ring and open-end spinning machine with

has the higher the energy consumption

n Energy consumption in yarn

Table 2. Energy consumption of specific combed ring yarn [13].

Electricity consumption of specific combed yarn

Ring yarn (Combed)

Table 4. Unit power consumption for chosen spinning mill.

Blow Room (Manuel1)

Blow Room (Manuel2)

Ring Traveler Robots

SUB TOTAL OF MACHINES

SUB TOTAL OF COMPRESSORS

SUB TOTALOF AR CONDITIONING

sumed energy which formed 78% of the

Table 5. Energy consumption for chosen spinning mill in May.

The amount of raw material R1 (kg)

Operating time for the first machine, t1

Blow Room (Cot-Linen Line)

Blow Room (Automatic)

Blow Room (Manuel1)

Blow Room (Manuel2)

Blow Room (Poly/vis)

Combing + Lap Machines

AIR CONDITIONING SYTEMS

Determination of energy consumption

Figure 1. Percent distribution of energy consumption in examined spinning mill; a) percent

Figure 2. Specific monthly energy consumption for spinning mill.

Here, N1 (kW) is the installed power of

machines, EM (kWh), can easily be calculated by the following equation.

where, EC expresses the total energy

Energy consumption of compressors for

where C1 (m3/h) is the compressed air

Energy consumption for machines and

ETA (kWh), is found as

Figure 3. The share of energy used for

As the machines in the blowing room

energy consumption for air conditioning

Table 7. Comparison of energy consumption.

20tex (Present Approach)

Table 8. Comparison of energy share of machines for 10tex yarn.

Calculated Data for

Table 9. Total energy consumption for chosen yarn.

Table 10. Specific energy consumption for chosen yarns [10].

carried out on the energy consumption

Here; F is the linear density of yarn

(e = 4) and Dr = 0.04 m. If these parameters are evaluated in the equation