Most manufacturing industries require steam boilers for accomplishing process operations. Steam is integral for various purposes of heating, drying, processing, sterilizing, etc. The textile industry is one such example that requires steam for its major processing stages. Textile is one of the ancient industries that have witnessed various changes and advancements over the centuries in terms of its processing. Several stages convert the raw fabric into a finished garment. Let us have a look at it in detail,
Yarn Manufacturing or Spinning:
The raw material or fiber and man-made fibers like synthetic or nylon are transported for yarn manufacturing. In this textile process stage, raw materials are converted into yarn for knitting, weaving, or crocheting. The raw materials are sorted and cleaned for creating the final yarn or thread.
Fabric Manufacturing or Weaving:
The next stage of fabric manufacturing involves transporting yarn from one machine to another in order to create a length of fabric.
The fabric wet processing operation includes dyeing and finishing of the fabric. The dyeing process introduces colors to the fabric, while the finishing process adds chemical properties such as anti-pill, soil release, flame retardant, etc., to enhance the fabric quality. The printing process includes inkjet printing on fabrics.
Garment Processing and Finishing:
The final process in the textile industry includes designing and sewing the final garments. It is followed by spot removal, ironing, and finishing before transporting it to markets.
Role of Steam Boilers in Textile Processing:
Steam boilers are indispensable in textile processing as the major process operations depend on steam or hot water generated from boilers. Textile processing units consider every factor before selecting a steam boiler that meets their demands effectively. Here are the primary stages of the textile process that requires steam or hot water,
The pre-treatment phase is one of the important stages in the textile process that involves the removal of dirt or impurities from the fabric before the dyeing and printing process. The pre-treatment stage requires efficient steam boilers to produce clean and pure steam or hot water.
The dyeing stage involves adding pigments or dyes to fabric to color them. Although the dyeing process can occur at any stage, it primarily occurs after the yarn manufacturing or fabric manufacturing stage of the textile process. The transfer of dye to the fabric requires a precise amount of moisture and heat provided by steam. Steam boiler enables the heating of water and steam at the determined temperature that is required to dye the fabric in exact color.
The printing stage in the textile process is similar to dyeing except that printing includes patterns or designs to the fabric, whereas dyeing includes uniform coloring. Depending on the type of fabric, the printing stage uses several methods. Steam boilers are essential for providing the precise amount of heat and moisture required for the printing process.
The finishing stage of the textile process involves several steps. It includes the removal of wrinkles from fabric. A steam boiler is vital for providing steam for the ironing purposes that provides excellent finishing.
Factors to Consider while Choosing Steam Boiler for Textile Process:
Deciding a steam boiler for the textile process is imperative to ensure optimal efficiency and productivity. Managers in textile processing units consider the following factors before determining their choice of steam boiler,
Seamless with Fluctuating Demand:
The steam requirements in textile process operations are fluctuating and require robust steam boilers that can effectively handle the changing demands. In such situations, steam boilers with a quick start or shut-off are best-suited for processing. Comparatively, water tube boilers perform better than fire tube boilers with the fluctuating load.
Due to fluctuating demand for steam, the textile process faces the difficulty of fuel wastage that leads to excess costs. Therefore, the steam boiler must perform effectively and ensure complete combustion to ensure optimal utilization of fuel.
Steam boilers in the textile process operate throughout the day and hence require regular maintenance for enhanced results. Negligence of boiler maintenance may cause boiler failure, resultantly shutting the textile process operations and leading to significant losses.
Calculating the Capacity and Heating Parameters of Steam Boilers:
The capacity of a steam boiler depends on the heating load that includes heat losses in boiler tubes and pipes. Additionally, the heating parameters like temperature and pressure must be determined.
With 38+ years of experience and expertise in thermal solutions, Rakhoh Boilers are the leading boiler manufacturer in India and overseas, with more than 3000 boiler installations in over 26 countries globally. Our Combo X model is the preferred steam boiler model in the textile industry. We have delivered our efficient steam boilers in over 360 textile process and dyeing units. Catering to 20 process industries worldwide, we manufacture steam boilers, waste heat recovery boilers, thermic fluid heaters, and boiler accessories. We offer the best boiler services like boiler automation, steam trap assessment, energy audit, annual boiler maintenance, etc to ensure hassle-free operations of steam boilers.
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