1. The document describes a conversion kit that has been designed to upgrade existing shuttle looms to more efficient rapier looms. 2. The conversion kit saves up to 20% on electricity usage and 2.7 MWh of energy per loom per year. 3. Implementing the conversion kit on 5 lakh looms could save Rs. 675 crore per year in electricity costs and reduce carbon emissions by 4 million tons of CO2, 24,000 tons of SO2, and 12,000 tons of NOx annually. 4. The conversion kit has been successfully trialled and implemented on looms in several Indian states.

1. Page 1 of 2 Converting Shuttle Loom to Rapier Loom5 PTO
Mr. Ravinder Vannam - Certified Energy Auditor: BEE -Mo: 07036199102: ravinder.vannam@gmail.com
Mr. Narendra Vannam – Textile Consultant -Mo: 09224973138: narendertex@gmail.com
Mr. Jagadishwar Chilivery - Textile Consultant -Mo: 09763269669
www.srisaitextileconsultancy.webs.com
Energy saving in Textile Industry
By Converting Shuttle Loom to Rapier Loom
A) Introduction:
Textile Industry is second largest Employment giving Industry next only to Agriculture, giving
employment to appox 34 million in India and earning Foreign Exchange due to Exports.
B) Background
Weaving of the cloth is done on Power Looms.
Presently there are millions of old Shuttle Power Looms in India. Shuttle Looms are very slow,
power consuming, noisy and laborious to operate. Shuttle is used to carry warp thread from one
end to other in Shuttle Loom. They stop every 2-5 minutes as pirn gets empty. Weaver has to take
out the shuttle, change the Pirn in Shuttle, match the colour, design & restart the Loom. This leads
to Quality problems & loss of Energy, production.
C) Modern Rapier/Projectile/Airjet/Water jet Machines are available in Market with high productivity:
They are imported from European countries/China etc and result in Forex out go & spare parts
availability problem. Also they are very costly for the Small /Micro scale operators in India. They
consume lot of Energy.
D) We have designed and developed a conversion kit for existing shuttle loom to Rapier Loom
i.e. In-Situ upgradation.
E) The advantages of conversion kit are as follows:.
OLD SHUTTLE LOOM
SHUTTLE WITH PIRN
RAPIER
NEW SLAY
CAM & DRIVE
MECHANISM
SHUTTLE BOX
Loom fitted with Rapier Mechanism:
Saves electricity upto 20%
Saving of Energy: 2.7MWH/ loom/year: This can illuminate 68
villages in India
Saving of Rs: 60,000/ loom/year
GHG reduction: 8Tons CO2: SO2: 49Kg: NOx 24Kg /Loom/yr
We can get Carbon Credits.

2. Page 2 of 2 Converting Shuttle Loom to Rapier Loom5 PTO
1. The mechanism invented saves electricity upto 20%.
2. Pirn winding process is eliminated.
3. Saving of Energy: 2.7MWH/Power loom/year, 1350 GWH /5Lac Looms/Year
4. Saving of Rs: 60,000/Power loom/year, 675Cr /5Lac Looms/Year- @5/unit
5. Saving of Rs: 52,000/Power loom/year, 338Cr /5Lac Looms/Year- @2.5/unit
6. Simple payback: 1.7Yr- }@5/unit: 1.9 yr- }@2.5/unit
7. Return on Investment 59% } @5/unit 52% } @2.5/unit
8. Increase in the productivity by min. of 30%- (depending on type/condition of Loom & yarn.)
9. It reduces the vibration of the machine.
10. It reduces the noise level of the machine.
11. Improve Ergonomics of m/c . Less fatigue on operator. It increases safety of the operator.
12. Improve Quality of the Fabric due to less stoppages & manual interventions.
13. Less skilled operators can handle the modified looms. There is scarcity of skilled labour.
14. Environmental benefits: Reduction in Carbon foot print (GHG-Green House Gas reduction)
and hence combating Climatic Change & pollution control. For 5Lac Looms/Year
Reduction in 1) CO2 :4Million Tons 2) SO2: 24,000 Tons 3) NOx : 12,000 Tons /year
15. Natural resources like Wood being used in shuttle is saved. And hence cutting of the trees is
avoided.
This will be cost effective to small players in Bhiwandi, Solapur, Ichalkaranji, Malegaon, Basmat,
Ahmed Nagar etc.
F) Progress made:
1. New Cam is designed and is made to convert rotary motion of Crankshaft to reciprocating
motion of Rapier, including dwell & syncronising with picking & beating motions of Loom .
2. New Slay is made to suit Rapier mechanism
3. One old Power loom is purchased for conducting modifications/trials. Prototype is ready.
4. Applied for the Patent.
5. Got commercial orders in Maharashtra & Telangana states.
6. Many Looms are modified in Solapur, Bhiwandi, Icchalkaranji & Sircilla. Working excellently
fine.
H) Market size:
1. Approx. 22 Lacs Shuttle looms still working in India.
2. Many old machines are working in Bangladesh/Srilanka etc.
I) Employment generation:
Employment generation for manufacturing of Kits, retrofitting: approx to 200 employees / state.
Awarded Innovation Award in DST (Dept.
of Science & Technology-Govt. of India)-
Lockheed Martin (USA) : India Innovation
Growth Programme 2014.