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Drying is often one of the most energy intensive operations in a wide range of textile processes.
The
implementation of an accurate on-line Moisture Control System can offer
significant benefits to processors involved in drying operations.
Direct Cost Benefits
All fibres retain a certain amount of moisture and this can have a significant effect on the total weight of the fibre.
As
the sale price of the fibre is often based on the weight of the fibre,
the amount of moisture can significantly affect the final sales value.
Generally the final invoice is adjusted to allow for the moisture content but this is not always the case.
It
is also often very important to monitor the moisture content throughout
the operation of a production unit in order to keep an accurate record
of yields. The effect of moisture variations of even 1% can have a
significant effect, especially for high value fibre.
Case Study 1
Consider the case of a slipe wool processor in New Zealand:
Annual production 500,000 kgs
Sell priceNZ$ 4.00/kg
Annual sale valueNZ$ 2,000,000.00
If
the regain could be raised by 1% this would equate to an increase in
revenue of NZ$ 20,000.00 per year. In this type of application a regain
increase of 2 to 3% is typical after the installation of a Streat
system.
Please note that above saving is just
the direct cost saving. There will also be considerable savings due to
reduced energy usage, increased productivity, and the ability to
optimise the operation (perhaps even saving on the cost of new capital
plant such as dryers as the old plant can be operated more efficiently).
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Case Study 2
Consider the case of a yarn spinner processing high value yarn:
Annual production 2,000,000 kgs
Sell priceNZ$ 300.00/kg
Annual sale valueNZ$ 600,000,000
A drop in yield of 1% (caused by moisture variation) would result in an apparent loss of NZ$ 6,000,000 per year.
This
is an extreme case with very high value yarn (cashmere) but even for a
yarn with a value of NZ$ 20.00/kg with the same production the apparent
loss would be NZ$ 800,000 per year.
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In addition there will also be considerable savings due to:
- Reduced energy usage (assuming the extra production capacity is not fully utilised).
- The
ability to optimise the operation (perhaps even saving on the cost of
new capital plant such as dryers as the old plant can be operated more
efficiently).
- More efficient use of labour.
Improved Downstream Processing
Improved future processing efficiencies are made possible if the product is kept at the desired level of moisture content.
The
problems caused by incorrect moisture can be considerable and in
extreme cases can result in damage to processing equipment. With the
modern high speed machinery optimum processing speeds can only be
obtained if the fibre moisture is controlled within tight limits.
Reprocessing can be eliminated if the moisture is correct first time!
Reprocessing and plant down-time reduce the time that the plant is available for normal production, and are thus very expensive.
These benefits can easily be directly related to total production to give annual saving.
Benefits of Improved and Consistent Quality
Improved quality has many benefits including:
- Increased competitiveness
- Competitive advantage over the opposition. This is especially relevant in times of difficult trading, tight margins etc.
- Satisfied customers resulting in fewer claims or complaints.
- Improved returns through the ability to sell more 'premium grade' product.
In
summary, the implementation of an accurate on-line moisture control
system should be considered by all processors looking to improving the
efficiency and profitability of their operations.
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