"Smarter Energy" - " textile plant energy saving and operation integration project " by Tai Yuen Textile
Tai Yuen Textile and IBM cooperated on "textile plant energy saving and operation integration project" collecting data from factory operations. This project leverages data analytics technology across all processes in the plant. The first phase resulted in 40% cost saving from air-condition electronic consumption and machine maintenance prediction. Furthermore, the real-time monitoring in air conditioning, especially the dust impact in the machine operation, the yield rate has been increased significantly.
1. Implement the data analytics among the whole plants operation. Adjust the procedure based on optimizing operations
2. Adjust and optimize operation of air-conditioning capacity of the supply and return air damper
3. Improve the heat exchange efficiency of air-washer
4. Optimize air-washers by monitoring & controlling the air-conditioning ice water volume
5. Design and build the Energy management system for textile plant on Cloud
Electricity costs are the largest expenditure of the textile industry. Due to transition toward green energy and environmental protection, TAI YUEN Textile collaborates with IBM Global Technology Services Division to introduce IT data center design & build methodology.
TAI YUEN Textile has plants in Jhubei, Chungli and Chunan, etc., and the annual electricity costs are up to several million US dollars. IBM Global Technology Services consultant analyzes the root causes and indicates that the spinning mill manufacturing process produces many batting floats in the air, once fall into cotton fabrics which are under production, the fabric will result in uneven quality, but also easily lead to spinning factory workers suffering from respiratory diseases. So the factory mounted motor and air-conditioning need to have a full-time operation to reduce the amount of cotton in the air. In the past, they used to recycle cotton amount by increasing conditioned air’s wind volume, but this contributed to the growth in electricity consumption; if reduce air conditioning for energy saving, cotton fall in the cloth will lead to lower yield. GTS leveraged the concept & methodology of data center design to propose a new lineup of plant; implemented the automated procedure with software defined to collect air quality, environment factors, power consumption, yield rate on cloud management platform. This innovative case effectively improved the environmental quality and product yield of the textile factory, and will be expanded to improve the results of the corresponding energy system equipment, and then will go further for smart plant architecture.
Energy Automation Monitoring Screen: can effectively monitor the energy consumption of the correctness of the equipment unit.