A recent German technology conference revealed a lot of machines and knowhows that were stunningly attractive to mills dealing with right from spinning to packaging. A packing machine showed how a pillow cover can be made from fabric and packed in a matter of four seconds! Ring spinning in a mill consumes nearly 50 per cent of the total power used in yarn making. The energy cost is around 15 per cent to 20 per cent over the production cost and it stands next to raw material cost.
Apart from using techniques to reduce power consumption, one cannot also ignore the emerging scenario in which speed and efficiency of production matters. When a mill upgrades, automation and energy-saving measures gain importance. With sustainability gathering momentum, the demand for the mills to invest keeps moving up. There are more challenges for other departments in a composite mill. For dyeing and finishing, about 150 litres water per kg of fabric are needed. Today, when companies are talking about technology that enables one to reduce water intake by 75 per cent or more, it is mind-boggling to see the very big cost reductions. According to a leading dye input manufacturer, a new range of reactive dye technology for cotton shows water and energy consumption can be reduced by a massive 50 per cent. Today, there has been a ‘quantum leap’ in technologies covering all the departments of a textile mill. Without automation and energy-saving techniques, mills may find it difficult to stay ahead in competition. It is high time Indian mills lend high priority to these aspects since the race to carve out a bigger share in profit is hotting up. Under the current situation, expecting results in ROI in the short term is like putting the cart before the horse! Investment needs quicker thinking with the objective of looking ahead considering all the important issues like automation and energy-saving steps. There are no options, and only dire necessities!