Smart Energy Consumption for Wet Processing

Energy and utility management is the key to improve business profit and production planning, since the cost of energy is the highest among all the other cost components in textile processing. We propose to develop an Innovative Energy and Utility Management System (IEUMS) using advanced sensor technology to obtain and monitor real-time energy utilization data (e.g. steam, water, electricity, etc.) and production information for cost analysis and energy consumption control to eventually achieve energy saving in textile processing. The project will directly benefit greatly the local textile industry; especially companies that consume huge energy and water. The technology, when fully deployed, will enable them to take remedial measures for cost reduction, to achieve better quality by minimizing wastages, to provide accurate costing with production status to senior management and customers, and to ultimately improve their business performance across the entire organization. The proposed system allows better control, monitoring and management of the production processing in a manufacturing plant.

The system is composed of a control panel equipped with keypad, radio frequency identification tags and tag reader, a wireless sensor network and a wireless meter data acquisition device. Wireless meter data acquisition devices are installed on water meters, electricity meters, steam flow meters and yard meters throughout the factory to obtain accurate energy consumption data and real-time production status. These data of the production floor will be transmitted to the back-end server for analysis through the wireless sensor network.

Industry Benefit

• Industrial-grade wireless transmission solutions: Embedded wireless data acquisition devices are suitable for a hot and humid industrial environment.
• Flexible installation: This system can adapt to different brand meters, including external or internal, digital or non-digital meters, and can be applied to existing meters.
• Time-saving: This system can provide highly accurate, real-time energy consumption data and reduce time on data entry manually.
• Intelligent computing: The system can facilitate intelligent energy consumption and production allocation that could reflect different levels of energy consumption and help establish indicators.
• Real-time system: The system can provide real time energy consumption and production status information with visual-user-interface. It also provides traceability and alerts functions.
• Flexibility: The system is especially oriented for different types of printing and dyeing sectors in the textile industry.

Technological Breakthrough

• Energy consumption measurement and analysis: Establish a comprehensive database on production energy consumption to understand the consumption status.
• Target setting and monitoring: Based on the energy consumption and production data management system, three branches of the energy-saving system can be established – energy consumption index at different levels, usage monitoring and performance assessment.
• Energy management: This can be achieved by using rationing, quota management, process operations management with the appropriate production scheduling, assessment mechanism and energy improvement projects.
• Solution assessment: This can improve the effects of the energy consumption assessment, as well as developing follow-up solutions.

Project Name (ITF)
Innovative Energy and Utility Management System in Textile Processing
Project Number (ITF)