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Waste management in the man-made fiber textile industry

Article in Chemical Fibers International · April 2021

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Ranjit Turukmane Sujit Shrikrushnarao Gulhane

Narsee Monjee Institute of Management Studies Narsee Monjee Institute of Management Studies
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Waste management
in the man-made fiber/textile industry
Constructing efficient measures for controlling operation waste provides an should implement both corrective and pre-
ventive actions when needed. Accordingly,
opportunity to assess how the organization manages detrimental losses,
effective implementation of management
and helps in finding better and more cost-effective solutions over the waste system in manmade plants will enhance the
generation in textile industries. By reviewing what the organization does and usage of the end product. The management
how well it works, the environmental management system can ensure to be system should help in redesign the products
or processes in order to optimize the used
viable and effective, both now and in the future, added to that, an effective
materials. In other words, the application of
environmental management system is built on total quality management a management system leads to cost reduc-
concepts. To improve the environmental working conditions, the organiza- tion, quality improvement, waste reduction
tion needs to focus not only on what things happen but also on why they due to redesign, proper equipment selection,
in addition to time savings.[2]
happen. Over the time the efforts taken by the industry management and
operative efficiency resulted in to identification and correction of system de- Analysis of waste collection and
ficiencies leads to better environmental and overall organizational perform- management
ance. The amount of waste an individual produces
is a small portion of all waste produced by the
man-made fiber industry, and process waste
Prakash Mahajan, Chetan Mali, process, maintenance of machines, workers reduction can make a big impact on overall
Ranjit Turukmane, Sujit Gulhane efficiency, etc. waste volumes. Yet influence on policy can be
MPSTME, NMIMS, Shirpur/India exerted in other areas. Increased manage-
Material and methods ment awareness of the impact and power of
Nowadays most textile industries are facing certain workers policy towards attending the
the problem of high waste generation in dif- Material breaks on individual machine. The readings
ferent sectors of the man-made fiber produc- Polyester partially oriented yarns (PET POY) were taken in standard atmosphere where the
tion industry. During spinning it was found were used for the experimentation and the work practices were solely responsible for
that the filament tow was collected several experiments were carried out in support with high waste generation in the POY section. The
times to pass it over the rollers to get the uni- man-made fiber production industry. The fol- study was conducted on each machine for 5
formity in the filaments, this would lead to lowing denier of filaments were considered days. The data was collected on real-time ba-
generation of waste which could be reused for the experiment: 250/144, 250/48, sis as shown in the table.
by re-melting it [1]. The waste generation has 500/96, 130/36 and 130/72. In Trial 1 the machine parameters were kept
a wide impact on the machine production, constant and data were recorded for 5 days.
efficiency and profitability of the textile in- Methods It was seen that the operator’s carelessness
dustry in global market. Waste management All samples made of PET POY were manufac- and improper handling of package during
is always a serious issue for many textile mills tured by using existing machinery setup with creeling was most common problem execut-
[2]. The cotton industries are prone to gener- standard machinery setting. ed during operation. Waste controlling tech-
ate a high amount of waste during fiber to niques were untraceable in the mill and fol-
yarn conversion process, this is unavoidable Result and discussion lowed by the poor work practices of workers
loss and nevertheless, when it exceeds the The objective of implementing a study in the and these will result into high waste genera-
stipulated level, it would result in monetary man-made industry is to reduce losses and tion. In all cases it was found that spinneret
loss to mills. Therefore, it is very important to generated wastes from improper production waste was found to be more during passing
take precautionary measures to optimize the procedures, packaging, used raw materials of filaments through the gun toward the
generation of various types of waste. In order and their bad handling and inefficient energy godets and if any oil stain was found on the
to reduce the mills losses, an effort should be consumption. Furthermore, an adopted package the worker used to remove layers of
made to find other ways to increase the pos- management system by a company is re- coils from the package [3].
sible sale value of waste in order to minimize quired to monitor waste levels, the system It is deduced from the table that in Trial 2 the
loss due to generation of waste.
The spinning waste of any industry depend
on the various factors such as type of ma-
chinery and condition. Work methods of op- Denier wise data collection and waste analysis
eratives decides the possible machine output
and level of waste generation. This could be Denier 250/48 130/72 D 250/144 500/96 D 130/36 D
controlled to a maximum extent without af-
fecting the machine productivity and yarn Average trial 1 [kg] 10.8 11 34 15 18
quality, by exercising a good control over the Average trial 2 [kg] 6 4.6 12 5 7.5

CFI 1-Mahajan – Fahne 1

average waste generation was considerably
reduced by adopting standard operating pro-
cedure. Regular staff evaluation should be
based on the actual data collected on real-
time basis to avoid any consequences in the
collected records, these evaluations need to
be honest and straightforward. It should be
focused on the management views as per the
areas of excellence and areas needing im-
provement. Regular maintenance practices
should be followed in the industry to replace
the worn parts to make the machine run to
give higher productivity and efficiency. Those
machines that continuously jam or break
down have a huge negative impact on ma-
chine production. Planned and scheduled
maintenance are critical to keeping machines
operating at their best for the longest
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stretches of time possible. The following ac-
tion was adopted in Trial 2 for waste opti-
mization
• operator was properly trained for attend-
ing faults
• excess weight was avoided
• the POY package was mounted properly
and operator was instructed not to col-
lapse the creeled package
• asked to do maintenance as per the sched-
ule.
Conclusion
Evaluating performance involves the regular
review of both waste use data and the activ-
ities carried out as part of the action plan.
Moreover, performance assessment and
goals setting cannot be done without analy-
sis of proper data. The monitoring system of
solid waste included daily data collection of
production, waste fiber generated from the
production line. The work practices followed
by the machine operators during production
resulted in the considerable reduction of
waste in the POY department.
References
[1] Kumar, R.S.: Process management in spin-
ning, CRC Press (2014), ISBN-13: 978-
1482208368
[2] Turukmane, R.N.; Borse, D.S.; Parsi, R.D.;
Dey, S.K.: Methods to control waste in multi-
plying process, Indian Textile Journal (2017)
10, 102-103
[3] Patil, P.M.; Turukmane, R.N.; Chandurkar, P.:
Mode of efficiency improvement by waste
minimization in draw texturizing process,
Man-Made Textiles in India 47 (2019)
154-156
CFI 1-Mahajan – Fahne 2