3.

Benchmarking
International Company Existing
No Deliverable parameters Unit of measure
benchmarking position
Blow Room
1 Temperature 0C 27-30 27-30
Relative Humidity:-
60-65
2 Mixing % 60-65
50-55
Blow Room 50-55
3 Efficiency % 70-75 75
4 Production kg/line/shift 1350/scutcher 1450/scutcher
5 Blow room dropping % 4 1-3
Cleaning efficiency of Blow
6 % 55-65 55
room
7 Sweeping waste % 1 0.5
8 Invisible loss & gutter loss % 1.5 1
Fire sensors & metal
9 Weekly weekly weekly
detectors checking
10 Jossi Vision shield checking Daily Daily Daily
11 Bale Management System Daily Bale Management Lot Management

23.01.24 Seite 1 1
Seite
3.Benchmarking
International Company
No Deliverable parameters Unit of measure
benchmarking Existing position
Carding
1 Temp 0C 27 - 30 27-30
2 Relative Humidity % 50 - 55 45-50%
3 Efficiency % 85-90 90%
320 kg/for
4 Prod/card/shift Kg/KG 320 Trutzschler

5 Waste extracted at card % 4-7 5

6 Card sliver trash % 0.15-0.5 0.1
For carded % 3.5 3.5
7 Card sliver Unevenness
For combed % 3.0 3.5
8 Trash in card sliver % 0.15-0.5 0.1
9 Card cleaning efficiency % 93-95 96-97
Combined cleaning
10 % 95-98 98
efficiency
11 NRE of card % 75-80 98
23.01.24 Seite 2 2
Seite
3.Benchmarking
International Company Existing
No Deliverable parameters Unit of measure
benchmarking position
Combing
1 Combing efficiency % 85-90 88
2 Prod/comber/shift kg 250 260
3 Comber Noil % 16-18 17
Usable waste at comber
4 % 1 1
preparatory & comber
5 Comber sliver un evenness % 3.5 3.5
Comber Neps removal
6 % 65-70 65-70
Efficiency
Drawng
Breaker Chinese draw frame 1275
8 KG 1100
Prod/Delivery/shift
9 Efficiency of Chinese Drawing % 75 - 80 75-80
Beakerr Chnese Drawing sliver
10 % 2.5-3.0 3.3
Unevenness
Finisher Rieter Drawing
11 kg 1200 850 kg
Prod/Deli/shift

23.01.24 Seite 3 3
Seite
3.Benchmarking
International Company Existing
No Deliverable parameters Unit of measure
benchmarking position
Drawing
Efficiency of Rieter Finisher
1 % 80 - 85 80-85
Drawing
Finisherr Rieter Drawing
2 % 2.0 2.0
sliver Unevenness
3 Sliver waste % 0.5 0.5
Roving
1 Production/ spindle /shift kg 4 kg/(HK rov 1.00) 4.2kg/spdl/shift
2 Roving frame Efficiency % 80-85 80-85
4.0 for carded
3 Roving Unevenness % 3.5
3.5 for combed
Speed frame end
4 % 3-4 2
breakages
5 Roving waste % 0.3 0.3

23.01.24 Seite 4 4
Seite
3.Benchmarking
Company
Deliverable International
No Unit of measure Existing
parameters benchmarking
position
Ring Spinning
7 Loss due to Doffing % 0.8 0.97
3.4
Yarn contraction for TPM 40S=1000
8 % 3.4
Twist Multiplier 4.00 TPI=25.4
TM=4.02
Pneumafil & Roller
9 % 2.5 0.2
bonda
2011
Carded=87.7
Combed=72.5
Carded= 87.5
10 Yarn Realization % 2012
Combed=71-73
Carded=87.3
Comber=72.7

Ring frame Spindle 23.01.24 Seite 5 5

Seite
3.Benchmarking
Company
Deliverable International
No Unit of measure Existing
parameters benchmarking
position
Ring Spinning
1 Temperature 0c 30 -32 28-32
42-48 Compact
section
2 RH % 50-55
50-55 Chinese
section
20sKH=9.5
30s KH=10
40sKH=11 40s Compact
3 Yarn Unevenness % 20sCH=8.5 CH=7.7
30s CH=9
40sCH=10
40s CH=8.76
30SV=9.78
20s=250
30s=170 40S=92
4 Ring Production Gms/spindle/shift 40s=120 60S=58
50s=80 50s=69
60S=62
23.01.24 Seite 6 6
Seite
3.Benchmarking
Company
Deliverable International
No Unit of measure Existing
parameters benchmarking
position
Rotor Spinning
Rotor Spinning Prod
1 % 92-95 92-95
Efficiency
98

Rotor Utilization 97
2 %
YARN REALISATION 87 89

20s=1.70
Rotor prod in 16= 2.38
3 % 10s=3.0
kg/Rotor/Shift 10= 3.90
7S/1=4.5
Auto coner
5 Auto Coner Efficiency % 70-75 78-80
20s=12 23.01.24 Seite 7 7
Seite
Auto Coner Prod in
3.Benchmarking
Quality control Auditing

International Company existing

No Quality parameters
Standard position
1 Count of Card sliver 0.100/5.9 GMS/M 5 GMS/M
2 Card Sliver CV% 3.5 1.5
3 U% Of Card Sliver 3.5 3.5
4 Count of Drawing sliver Breaker 5,9 GMS/M 5.5
5 Count of Drawing sliverg Finisher 5.9GMS/M 5.5
6 Drawing Sliver CV% Rieter 0.5 0.4
7 Drg U% Rieter 2.0 2.2
8 Count of Unilap 75 GMS/M 72 GMS/M
9 Count of Comber sliver 5.9 GMS/M 4.2
10 U% Of Comber sliver 3.0 3.6
11 Comber Noil% 16 -18 17
12 Count of Roving 1.00/0.59 0.65 GMS/M

23.01.24 Seite 8 8
Seite
3.Benchmarking
International Company Existing
No Quality parameters
Standard Position
20=3.5
13 Roving U% 30/40S=3.0 40s=3.5

20s16.5 20s=17
30s=17 30s=17
14 Ring Frame Count RKM 40s=17 40s=18
60s=18
60s=20.5
20s=1700
No instrument to
15 CSP 30s=1800
40s=2000 check
30s=1
30=0.71
16 Count CV % 40=0.75 40s=1
60s=.1.0 60s=1
No instrument to
17 Test CV% 2.5
check
18 TPI CV% 2.0 2.0
40s
20S CH=8
COMPACT=7.72
19 Yarn U% 30sCH=8.7
40sCH=9.5 40SCH=8.76
23.01.24 Seite 9 9
Seite
3.Benchmarking
International Company Existing
No Quality parameters
Standard Position
30=0
Compact40sCHs=00
20 Thin places 40=2
60s=5 40sCH=00
20=7
Compact40s=2.3
21 Thick places 30=15
40=35 40s CH=6
20=10
Compact40s=3.8
22 Neps 30=25
40=30 40sCH=33
20=17
40Compact=6.1
23 Total IPI 30=40
40=67 40sCH=39
20=16
Compact40s=17
24 RKM 30=16.5
40=17 40s CH=19.7
20=9
25 RKM CV % 30=8.5 Not available
40=8.5

23.01.24 Seite 1010

Seite
3.Benchmarking
International Company Existing
No Quality parameters
Standard Position
30=5.2
40sCH=5.4
26 Elongation 40=5
60s= 30s V=10
27 Elongation CV% 8 Not available
20CH=5.75 Compact40sCH=
Yarn Hairiness
28 30CH=4.5 3.27
40CH=4
40s CH=4.0
20s=60
Australian
29 AFIS Taste Neps in Mixing 30s=90
40s=120 cotton=201
20s=100
30 Neps in chute 30=160 40s=200
40s=220
20s=30
31 Neps in card sliver 30s=45 40s=50
40s=60
20s=70
32 Neps removal efficiency of card 30s=72 80
40s=73
23.01.24 Seite 1111
Seite
3.Benchmarking
International Company Existing
No Quality parameters
Standard Position
20s=120
33 Neps in lap of Unilap 30s=130 40s=50
40s=150
20s=35
34 Neps in comber sliver 30s=36 40s=16
40s=45
20s=71
Neps removal efficiency of
35 30s=73 70
comber
40s=70
36 A% of Rieter Drawing 0.5 No checking
37 Stretch% of roving 1% No checking
40sCOMPACT=
Yarn quality at per 2007 Uster
38 5-25% 5%
Standard
40sCH=5-25%

23.01.24 Seite 1212

Seite
3.Use of cotton in the
mill

Parameters
Length 30.01 MM Australian S M Leo 5/32
Mic 4.29
Maturity 0.89%
Uniformity 81.7
SFI 8.4
Strength 32.4 GMS/TEX
Elongation 5.3%
Moisture 7.0%

23.01.24 Seite 1313

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4. 节能措施

节能点 1: Yarn Conditioning Plant 纱线性能提升车间

Actual Situation:
现状

The mill does not have any yarn conditioning plant.

工厂没有纱线性能提升车间
The function of yarn conditioning plant is primarily for twist setting along with improving the
elongation & strength in yarn which improves yarn quality.
纱线性能调节车间的作用主要是通过设定捻度、增加强度和伸长性来改善纱线质量。
Also this process increases the moisture regain by 1.5%. The yarn production of 2012 was
13539 t
此工序可以使纱线增加 1.5% 的湿度。纺织厂 2012 年纱线的产量是 13539 吨。

23.01.24 Seite 1414

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4. 节能措施
节能点 1: Yarn Conditioning Plant
FOTO
纱线性能提升车间
Optimised Situation:
Implementation of yarn conditioning plant
最佳模况：使用纱线性能提升车间
Production 产量 13539t/a ，年产 13539 吨
Humidity increase 湿度增加率 1,5%
Production increase 产量增加值 203t/a ，年产 203 吨
Spec. earning 特定收益 18CNY/kg ， 每公斤 18 元
Additional earnings (excl. additional. energy costs) 额外收益（不包括，额外能源成 万 CNY/a ，每年 366 万
本） 366元
Additional energy costs （额外能源成本率） 10%
万 CNY/a, 每年 36.6 万
Additional energy costs （额外能源成本） 36.6元
Additional earnings （额外收益） 329万 CNY/a 每年 329 万元

23.01.24 Seite 1515

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4. 节能措施
节能点 1: Yarn Conditioning Plant 纱线性能调节车间
Optimised Situation: If energy saving would like to be FOTO
achieved, equipment could be turned off after 98.5% of actual
production time
最佳情况：要达到节能，设备需要在实际生产时间的 98.5% 以
后关闭 ( 增加湿度产能提高 1.5%) 。

Energy Consumption 能耗 6822万 kWh/a 每年 7100 万千瓦时

Reduction of production time 生产时间减少率 1,5%
Energy saving 节能率 1%
Energy saving 节约的能源 68万 kWh/a
Electricity tariff 电价 0.68CNY/kWh

Energy saving 节能的能源价值 46.4万 CNY/a

Investment 设备费用 90万 CNY
Pay back period 投资回收期 0.3* a

* Short pay back period due to additional earnings

23.01.24 Seite 1616
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4. 节能措施

节能点 2: Humidification Plant 增湿车间 FOTO

Actual Situation: The humidification plant is manually operated in 100000
spindle plant. Hence Temp & RH% are controlled bihourly to avoid
disturbances in working. Motors are operation all the time.
最佳情况：增湿车间是在 10 万锭的车间内人工操作的。因此，每两小时对温
度和相对湿度进行调节，这样不会影响生产秩序。电机在生产期间不停止运
作。

Total energy consumption 总能耗 6822万 kWh/a

Total number of Spindles 环锭总数 140000
Spec. energy consumption 特定能耗 487万 kWh/a
Spindles in 100000 spindle plant 10 万锭车间纱锭数量 100000
Energy consumption in 100000 spindle plant 10 万锭车间能耗 4873万 kWh/a
HP energy consumption in 100000 spindle plant 10 万锭车间增湿车间能耗率 25%

HP energy consumption in 100000 spindle plant 10 锭车间增湿车间能耗值 1218 万 kWh/a

23.01.24 Seite 1717

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4. 节能措施

节能点 2: Humidification Plant 增湿车间

Optimised Situation:
Temp & RH% must be recorded every hour.
Some of the motors can be turned off during night time, rainy and winter season to save energy
by 5%.
最佳情况：
必须每小时对温度和相对湿度百分比进行记录
夜晚，雨季和冬季关闭一些电机，可以节约 5% 的能源

HP energy consumption in 100000 spindle plant 10 万锭车间增湿车间能耗值 1218 万 kWh/a

Energy savings 节能率 5%
Energy savings 节能的能源总计 61 万 kWh/a
Electricity tariff 电价 0,68CNY/kWh
Energy saving 节能的能源价值总计 41.4 万 CNY/a
Investment 投资 0CNY
Pay back period 投资回收期 - a

23.01.24 Seite 1818

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 4. 节能措施
节能点 3 ： Speed increase of Ring Frames

提高细纱机运作速度
Actual Situation:
The unit consumption for producing 1 kg of 21s yarn (UKG) is
3.75 kWh as against 2.0 kWh at 40s combed conversion .The
average production/day in the year 2012 was appx 39 t
现状
生产 1 公斤 21 支纱线的单位能耗（ UKG) 是 3.75 千瓦时，而不是
2.0kwh （国际标准） . 2012 年的天平均产量总计约为 39 吨

Spec. consumption 特定能耗 1.671kWh/kg 21 count 21 支 每公斤 1.671 千瓦时

Conversion factor 转换因素 0.44521 Count/40Count Standard 每 40 支标准 0.44521 支
Spec. consumption 特定能耗 3.755kWh/kg 40 count 40 支 每公斤 3.755 千瓦时
Target value 目标值 2.0kWh/kg 40 count 40 支 每公斤 2.0 千瓦时

23.01.24 Seite
Seite 19
1919
Seite
Seite 19
4. 节能措施
节能点 3 ： Speed increase of Ring Frames

细纱机提速
Optimised Situation:
If the mill could have produce 5% more production, the consumption & cost of power for
Humidification plant, chiller, compressor & lighting would remain same or almost constant
which accounts appx. 30-35% of total power costs
最佳情况：
如果产量提升 5% ，增湿车间、制冷、空压和照明的能耗及其费用将基本保持不变，而这些设备
在总能耗中占比 30-35%

Production 产量 13539t/a 每年 13539 吨

Production increase 产量增加率 5%

Additional production 所增加的产量值 676.95t/a 每年 676.95 吨

Spec. earning 特定收益 18CNY/kg 每公斤 18 元

Additoinal earnings 额外收益 1218.5 万 CNY/a 每年 1218.5 万元 CNY/A

23.01.24 Seite
Seite 20
2020
Seite
Seite 20
4. 节能措施
节能点 3 ： Speed increase of Ring Frames
Optimised Situation:
If energy saving would like to be achieved, equipment could be turned off after 95% of actual
production time.
最佳情况：
要节能，设备在实际生产时间的 95% 后应关闭。
Energy Consumption 能耗值 6822万 kWh/a 每年 7100 万千瓦时
Energy Consumption HP, chiller, compressor & lighting, …
增湿车间，制冷，空压和照明设备的能耗 35%
Savings 节能率 5%
Energy Savings 节能值 119.4万 kWh/a 每年 124.3 万千瓦时
Electricity tariff 电价 0.68CNY/kWh 每千瓦时 0.68 元
Energy saving 节能值 81.2 万 CNY/a 每年 84.5 万元
Investment 投资 0CNY 0 元
Pay back periode 投资回收期 - a 无

23.01.24 Seite
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2121
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Seite 21
4. 节能措施
节能点 4 ： Illumination 照明

Actual Situation 现状 :
FOTO

Lamps 灯 1200Pices 1200 支

Lamp capacity 灯的容量 2x36W 72 瓦
Lamp capacity 灯的容量 72W/lamp 每支灯 72 瓦
Total capacity 总容量 86,4kW 86.4 千瓦
Operating hours 运行时间 8760h/a 每年 8760 小时
Energy consumption 能耗 75.7万 kWh/a 每年 75.7 万千瓦时

23.01.24 Seite
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2222
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Seite 22
4. 节能措施

节能点 4 ： Illumination 照明
工厂的照明程度太高

纺织业照明标准（；勒克斯）
Department 工序 Good Average Poor
Blow room, humidification
plant & packing 开清棉、增 50 40 < 25
湿和包装车间
Preparatory
70 50 < 40
准备纺纱
Spinning, doubling & TFO
100 75 < 60
纺纱、并纱和倍捻
Post spinning 后纺 150 100 < 60

23.01.24 Seite
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2323
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Seite 23
4. 节能措施

节能点 4 ： Illumination 照明
Optimised Situation: The authority can switch off a few rows of tube light to reduce
power consumption by 10% or otherwise there are 2 lights in one shade. One tube light
can be taken out from the shade keeping only one tube light in one shade. In this way
the mill authority can save energy consumption by 10%.
先进模式：主管可以关掉几排灯，节约 10% 的能耗
Energy savings 能源节约率 10%
Energy savings 节约的能源总计 7.6万 kWh/a
Electricity tariff 电价 0.68CNY/kWh
Energy saving 节约的能源价值总计 5.1 万 CNY/a
Investment 投资 0CNY
Pay back period 投资回收期 - a

Weiters: Austausch der T8 auf T5 Leuchtmittel prüfen

23.01.24 Seite
Seite 24
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Seite 24
5. 管理建议

•The Mill having 18 transformers with a capacity of 24.76 MW. The consumption load of
transformers are appx 40% instead of 60-65%. The Management should think how to
increase load at 50-60% to reduce energy loss.
•厂里共有 18 个总容量为 24.76 兆瓦的变压器，变压器载荷约为 40% ，没达到 60-65% 。
•领导应考虑如何提升至 60-65% 减少能源损失。

•There are 3 compressors installed in the factory. Out of 3, one compressor is working
continiously, one intermittently and the 3 rd one is idle. The base compressor which is
working continuously is loosing its life span than the compressor which is working
intermittently. Hence both the compressors should be used to run continuously alternately
every week.
•厂里有 3 个空压机，其中 1 个是持续运作的，另一个是间歇性运作，第 3 个没有用起来，持
续运作的空压机比间歇运作的空压机损耗大，因此需要每周交替使用这两个空压机，平衡两
者负担。

23.01.24 Seite 2525

Seite
5. 管理建议

•There is no colour coding in Card & Blow Room pipe lines for easily
understanding which pipe line is carrying raw materials & which pipe
lines for waste or micro dust.
This should be done for detection & easily attending break down.
开清棉和梳棉车间内原棉、废棉和微尘三条管道没有标上不同颜色进行
区分。做颜色标记可以帮助检查和分析故障。

•For the upcoming 80000 spindles the mill should purchase 3 or 4

different colour card & Drawing cans for segregation of counts to avoid
purchase of extra colour bands to save cost of bands as well as
manpower.
•对即将投产的 8 万锭车间而言，应购买 3 或 4 种颜色各异的梳棉和并条
筒用来放置支数不同的纱线，减少色带的数量，节约色带和人力成本。

23.01.24 Seite 2626

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谢谢！

23.01.24 Seite 2727

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