1 INTRODUCTION
The textile industry occupies a vital place in the Indian economy and contributes substantially to its exports earnings. Textile exports represents nearly 30 percent of the country‘s total exports. It has a high weight age of over 20 percent in the national production. India is the world’s second largest producer of textiles after China. It is the world’s third largest producer of cotton – after China and the USA – and the second largest cotton consumer after china. The textile industry in India is one of the oldest manufacturing sectors in the country and is currently it’s largest.
The textile industry occupies a unique place in our country. One of the earliest to come into existence in India , it accounts for 14 percent of the total industrial production, contributes to nearly 30 percent to the total export and is the second largest employment generator after agriculture. The Indian textile industry is one of the largest in the world with a massive raw material and textile – manufacturing base. Indian economy is largely dependent on the textile manufacturing and trade in addition to other major industries about 27 percent of the exchange earning are on account of export of textile and clothing alone. The textiles and clothing sector contributes about 14 percent to the industrial production and 3 percent to the gross domestic product of the country. Around eight percent of the total excise revenue collection is contributed by the textile industry. So much so, the textile industry accounts for as large as 21 percent total employment generated in the economy. Around 35 million people are directly employed in the textile manufacturing activities.
1.1 HISTORY OF TEXTILE INDUSTRY IN INDIA
India has been well known for her textile goods since very ancient times. The traditional textile industry of India was virtually decayed during the colonial regime. However, the modern textile industry took birth in India in the early nineteenth century when the first textile mill in the country was established at fort gloster near Calcutta in 1818. The cotton textile industry, however, made its real beginning in Bombay, in 1850s. The first cotton textile mill of Bombay was established in 1854 by a Parsi cotton merchant then engaged in overseas and internal trade. Indeed, the vast majority of the early mills were the handiwork of Parsi merchants engaged in yarn and cloth trade at home and Chinese and African markets. The first cotton mill in Ahmadabad, which was eventually to emerge as a rival centre to Bombay, was established in 1861. The spread of the textile industry to Ahmadabad was largely due to the Gujarat trading class. The cotton textile industry made rapid progress in the second half of the nineteenth century and by the end of the century there were 178 cotton textile mills; but during the year 1900 the cotton textile industry was in bad state due to the great famine and a number of mills of Bombay and Ahmadabad were to be closed down for long periods.
The partition of the country at the time of independence affected the cotton textile industry also. The Indian union got 409 out of the 423 textiles mills of the undivided India. 14 mills and 22 per cent of the land under cotton cultivation went to Pakistan. Some mills were closed down for some time. For a number of years since independence, Indian mills had to import cotton from Pakistan and other countries. After independence, the cotton textile industry made rapid strides under the plans. Between 1951 and 1982 the total number of spindles doubled from 11 million to
22 million. It increased further to well over 26 million by 1989-90.
22 million. It increased further to well over 26 million by 1989-90.
1.2 GENERAL DESCRIPTION ABOUT THE ENERGY CONSERATION PATTERN IN TEXTILE INDUSTRY
Textile industry is an energy intensive industry and more so is textile wet processing. The break – up of energy consumption during the various operation of spinning, weaving and wet processing of textile report for UK and the Indian textile industry is as follows
UK India
Spinning 25% 24%
Weaving 23% 28%
Wet processing 52% 48%
From the above figures it is evident that wet processing operation consumes almost 50% of the total energy requirement of a composite textile mill. This is an attributable to the fact that wet processing operation involves heating of large quantities of water, drying of wet fabric, high temperature such as heat setting, high temperature, dyeing and curing operation etc.
Steam plays a vital role in the wet processing of fabrics not only due to the fact that steam cost is more than 30% of the total processing cost but also if steam quality is good, cloth processing is also good.
The consumption of utilities for mill processing cotton will be as under:
Steam 12.3 kg/kg
Power 0.73 kwh/kg
Water 13.3 lit/m
In spite of such an important role of steam for cloth, processing, generally the aspects of steam generation, distribution and the Utilization are neglected in most of the textile mills.
For a textile unit, processing around 40,000 meters of cloth per day the fuel consumption varies around 10,000 (Rs.) which is 10% of total sales
Due to depleting nature of fossil fuels the cost and avail ability of coal/oil both will be problem in near future. So the role of steam will be further enhanced and this is going to be a major deciding factor in the survival of composite and processing units.
1.3 TEXTILE CLUSTER OF PALI DISTRICT
In textile cluster of Pali district (Rajasthan) mostly wet processing is carried out. In wet processing, dyeing & finishing of fabric take place. Dyeing & finishing process are the major energy consuming areas. In these processes mainly thermal & electrical energy are used. It is known that thermal energy in textile mill is largely consumed in two operations, in heating of water & drying of water. Fuel consumption in textile mills is mostly directly proportional to amount of water consumed. Hence if consumption of water can be reduced, it will also save energy. Conservation of energy can be affected through process and machine modification, proper chemical recipes and new technologies. In Pali the annual turnover is shown in fig. 1 where the colors of the bars represent the rupees in lakh and no. On the bars represent the no. of textile units. The annual production is shown in fig 2 where the color bars represent the no. of production in meters and the no. On the bars represents the no. of textile unit.
Fig. 1.1 Annual turnover of cluster of textile unit located in Pali district
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Fig.1.2 Annual production of cluster of textile unit located in Pali district
1.4 PHYSICAL LOCATION OF RESEARCH ACTIVITY
The small scale textile industries of Pali city are located at Mandia road industrial phase 1 of Pali city and medium scale textile industries are located at industrial phase 2 and phase 3 of Pali city
Fig 1.3 Physical location of research activity
Fig 1.4 Physical location of research activity
1.5 HORIZON OF PROBLEM AND OBJECTIVE OF PRESENT STUDIES
A comprehensive survey of the issues associated with the current performance level of the textile industries of Pali cluster was carried out. The objective of the survey was to identify the barriers that are responsible for the poor energy efficiency levels and technological obsolescence of the industry as compared to the developed countries. The textile industries of Pali cluster mainly comprises of Small and Medium Enterprises (SMEs). Besides these the survey unveils the real facts associated with the Textile industries of Pali Cluster. Ten Textile industries were surveyed. In this assessment the industries of different types and capacities have been thoroughly analyzed.
Through this sectoral analysis of Textile industry an attempt has been made to identify the energy conservation opportunities in the Textile industries sector and to find out the various ways to improve the overall performance of these industries. Further the effect of implementation and financial analysis of Energy Efficient (EE) technologies in the sector has been examined.
