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Power Consumption in Ring Spinning Mills

Two types of energy can be used in a specific spinning mill; electrical energy and thermal energy. Machines, air conditioning, lamps used for illumination and compressors consume electrical energy while the thermal energy is consumed by air conditioning and processes such as fixation of yarns.

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Power consumption at various stages of spinning

General energy usage in ring spinning Energy is generally used for operating machines, air conditioning and illuminating the atmosphere where yarns are manufactured in spinning mills. In addition to these, compressors which provide compressed air to the spinning line use energy. Two types of energy can be used in a specific spinning mill; electrical energy and thermal energy. Machines, air conditioning, lamps used for illumination and compressors consume electrical energy while the thermal energy is consumed by air conditioning and processes such as fixation of yarns. Generally, thermal energy is obtained from coal, diesel oil, fuel oil, natural gas, and steam.

The table shows the energy consumption of a specific combed yarn in a modern factory with its production steps. It can be seen from the table that 221.1kWh energy is used for a given spinning line of 1000 spindles, 61% of which is consumed by machines and the highest energy consumption with 30% share occurs at the spinning stage.
Energy consumption of specific combed ring yarn.

Production StepsElectricity consumption of specific combed yarn per 1000 spindles for each process
kWh/1000 spindlesShare, %
Blowing Room16.77.5
Carding17.78
Combing10.95
Drawing-Roving9.14
Ring Spinning66.130
Yarn Finishing Treatments14.76.5
SUB TOTAL135.261
Air Conditioning85.939
TOTAL221.1100

Energy usage for the specific ring and open-end yarn.

The energy usage and energy cost of both 20 tex combed ring-spun yarn and 20 tex open-end yarn for the chosen countries are illustrated in the following table. The amount of energy needed for ring yarn changes between 3.49 – 3.62 kWh/kg while the energy needed for open-end yarn is between 2.44 and 2.58 kWh/kg. Since the electrical energy prices are different in the chosen countries, the energy cost differs from country to country although the consumption is nearly the same.

Energy usage for a specific ring and open-end yarn.

CountriesElectrical energy prices, $/kWhRing yarn (Combed)Open-End Yarn
Energy consumption, kWh/kgEnergy cost, $/kgEnergy consumption, kWh/kgEnergy cost, $/kg
China0.0663.490.232.580.17
India0.0843.570.302.500.21
Turkey0.0703.570.252.570.18
Brazil0.0313.540.112.580.08
S.Korean0.0473.620.172.550.12
USA0.0453.560.162.440.11
Italy0.1053.520.372.570.27
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