Improving energy efficiency in textile processing

The ISO 50015 and IPMVP-approved energy efficiency service provided by Klüber Lubrication ensures that the users of the service can clearly monitor the energy consumed by the machine and helps users understand the exact measure of energy saved post the lubricant switch

Improving efficiency and extending machine service life with appropriate lubrication are key factors in making the textile industry more sustainable. A leading textile processing plant sought the expertise of Klüber Lubrication India (P) Ltd. to improve energy efficiency in their processing unit. It also availed ISO 50015 approved energy efficiency monitoring service of Klüber Lubrication which follows the International Performance Measurement and Verification Protocol (IPMVP). This solution helps in reducing the energy consumption of the customers.

The ISO 50015 and IPMVP-approved energy efficiency service provided by Klüber Lubrication ensures that the users of the service can clearly monitor the energy consumed by the machine and helps users understand the exact measure of energy saved post the lubricant switch. Previously, the customer was using a synthetic hydrocarbon oil of grade ISO VG 220 and was facing several issues like higher energy consumption, temperature fluctuations and high loads, among others.

Pre-Treatment Range Gearbox Lubrication Challenges

When it comes to the PTR gearbox in the textile industry, accuracy and control are critical. Therefore, finding the right lubricant which can improve machine efficiency while enabling the user to act in a sustainable manner and protect the environment was crucial. As per ISO 50015 and IPMVP, the methodology followed by the Klüber Energy Efficiency service was to measure the energy consumed by the gearbox over a certain time period. Over this time, a study was done to identify the impact most of the influencing variables have on the energy consumption of the gearbox.

Once the initial data collection and study was complete, a mathematical model was built which could correctly predict the energy consumption of the gearbox. To fine tune and test the accuracy of the model, the predicted values from the mathematical model were benchmarked against the actual measured values. Once the mathematical model was able to predict the energy consumption as close to the actual consumption of the gearbox, the lubricant was switched in the gearbox and energy consumption with the new lubricant was compared with the values from the mathematical model.

Klübersynth GH6-220: A Sustainable Solution

After conducting a thorough analysis of the user requirements, the team of experts at Klüber Lubrication came up with a solution that was not only efficient but also highly sustainable – Klübersynth GH 6 -220. This synthetic high-performance gear and high-temperature oil based on polyglycol is highly suitable for the growing requirements and increasing power density of modern gears. After shifting to Klübersynth GH6-220, there was a significant improvement in energy efficiency. After the shift of the lubricant the user saw a reduction in energy consumption to the tune of more than 10%.

Moreover, Klübersynth GH6-220 ensured a considerably lower consumption of natural resources, less waste, cost-effectiveness and increased occupational safety. Klüber Lubrication’s solution not only provided an efficient and reliable lubricant to the user but also made a significant impact on their contribution to sustainability. The energy efficiency provided by Klübersynth GH 6- 220 in one single gearbox is equivalent to planting 170 trees per year.