1. Gaurav Katre
M Tech
1st Year

2. Bruckner
 Be the First in Finishing
 German Company
 Run by Leonberg Family
 Tailor-made Lines
 Complete system for Textile Finishing

3. Initiatives
 Continuous Increase in Energy Prices
 Market is Competitive
 Future investment in energy saving is important
 Optimized energy efficiency production lines
 ITMA ASIA 2010
 Power Frame Stenter
 Eco- Heat
 Eco- Air

4. POWER-FRAME stenter

5. POWER-FRAME stenter
 New Generation Stenter
 Highest Performance
 Minimum energy consumption
 Split flow System
 Patented Venturi nozzle: optimum mixture of circulating and
fresh air
 Homogenous air distribution : alternating air flow in the
thermo zones.
 Robust and low-maintenance chains

6. Save Hard cash with ECO Heat

7. ECO Heat System
 Heat the fresh air or water by exhaust air
1. Air to Air :
 Heat of exhaust gases is used to heat the fresh air
 It can reduces process heat demand by 12 to 15%
 In case of dry heat setting it is upto 30%.
2. Air to Water:
 Water can be heated up to 900C
 Can be used directly to process/boiler feed water.

8. Line Diagram of Air / Air heating

9. Line Diagram of Air / Water heating
Incoming Water
Air Out
Out going
Water
Air In

10. Advantages of ECO Heat recovery
 Energy savings of up to 35% depending on the process
 Very short pay back time
 Retrofit to older lines and machines supplied by other
producers
 Integrated into the stenter roof structure
 Low floor space

11. Combined Air/Air and Air/Water system.

12. ECO Air System
 Self-cleaning scrubber zones
 Electro static filter system
 Offers air filtration in two
stages through:
 Ionization Zone
 Collection Zone
 This system filters air with 99%
of efficiency
 Available with integrated
automatic cleaning unit

13. Advantages of Eco – Air
 More efficient than devices only with ionization zone
 Available in several sizes
 High removal efficiency for aerosols and noxious gases
 Low cost of operation
 Robust design in stainless steel
 Compact dimensions
 Easy maintenance with compact filter modules: easy to remove
and easy to clean

14. Eco – Heat Statistic
 Temperature inside stenter 2200C
 Exhaust Air Temperature 1400C
 Heat recovery system can recover 700C
 Energy saving of up to approx. 20 %with 140°C dryer
temperature
 Energy saving of up to approx. 35 % with 190°C dryer
temperature

15. Case Study : Lucky Tex Processing Mill, Pakistan
 Lucky Tex domiciled in Karachi
 Owing weaving mills, finishing, dyeing and drying facilities as
well as stitching unit
 Total capacity of 225,000 meters /day
 Three Bruckner Power Frame Stenters installed at Lucky Tex
for drying and heat-setting of woven fabrics
 Lucky Tex has installed ECO-HEAT back-pack – heat recovery
air/air integrated into the top of the dryer
 Integrated into the roof of the dryer
 Annual costs associated with stenter operations, almost 60% of
total annual cost
 Almost 25% cost reduction with a Bruckner heat recovery

16. Case Study : Lucky Tex Processing Mill, Pakistan

17. Project Report On Installation Of Waste Heat Recovery
System In Stenter at Pali
 Bureau of Energy Efficiency (BEE) is implementing a BEE-
SME Programme to improve the energy performance in 25
selected SMEs clusters
 Pali Textile Cluster is one of them
 Today there are over 350 units in Pali
 Production of all of these combined together crosses 5.5
million meter per day
 Energy account for 30% on total cost

18. Potential
 Electricity consumption for stenter alone in textile dyeing and
processing units , 50%
 Over 20% for electricity consumption
 30% fuel consumption in power process industries
 Pay back period of less than one year

19. References
 Report on Detailed Project Report On Installation Of Waste Heat Recovery
System In Stenter (Pali Textile Cluster) by Bureau of Energy
Efficiency, Detail Project Report No.: PAL/TXT/WHR/15
 www.bruckner.com
 Ali Hasanbeigi , Energy-Efficiency Improvement Opportunities for the
Textile Industry , Ernest Orlando Lawrence Berkeley National
Laboratory, September 2010
 Amina Baqai, Brückner Stenters and ECO-HEAT back-pack – heat recovery
unit on dryer lower the energy consumption and other inputs at Lucky Tex
Processing Mills, Pakistan textile journal, October 2012
 http/: splitflowpumps.com
 S. Petra Lehner, systems supplier Brückner presents efficient
solutions, Pakistan textile journal, March 2011
 Energy Saving Technologies: Spotlight of Finishing Sector , by fibre2fashion