Energy Consumption Analysis and Optimization in a Spinning Mill using IEM Tools

Anand Prasad; Johan George Cherian

Energy Consumption Analysis and Optimization in a Spinning Mill using IEM Tools

Author(s)	Mr. Anand Prasad, Mr. Johan George Cherian
Country	India
Abstract	Commercial textile spinning is a manufacturing field that consumes very large amounts of energy, and the price of electricity has an immediate effect on operating spending, competitive position, and long-term business survival. In this work, an end-to-end, data-centered optimization approach is presented for a nonstop spinning plant, bringing together several analysis tools drawn from industrial engineering and operations management. The mill examined shows a high electrical load pattern, with yearly grid use measured at 8.31 million kWh and an electricity bill totaling ₹6.33 Crores. To address embedded inefficiencies and cut expenses while staying within a fixed yearly CAPEX limit of ₹25 Lakhs, a broad, multi-tier optimization program was developed. Initially, a combined AHP and TOPSIS method was used to rank eleven proposed energy-saving initiatives. Next, a 0–1 integer LP formulation computed the best package of actions while respecting constraints tied to resources, capacity, and organizational limits. After that, a 2^3 full factorial DOE was applied to refine key operating variables in the largest energy-using area, namely the ring spinning frames. Changes tested in the experiments led to a strong drop in SEC for the ring frames, moving from 2.85 kWh/kg at the starting point to 1.93 kWh/kg after optimization, which corresponded to a plant-level yearly reduction of 1,250,000 kWh. Ongoing stability in operations was supported using a quantified FMEA that lowered implementation risk by 78.5%, and Shewhart SPC confirmed a very capable process (Cpk = 1.8) across a 120-day observation period. The implemented modifications delivered repeat utility savings above ₹2.14 Crores each month, creating a scalable reference standard for sustainable manufacturing worldwide in process-based industries.
Keywords	Energy Optimization, Specific Energy Consumption, AHP-TOPSIS, Zero-One Linear Programming, Design of Experiments, Statistical Process Control, Failure Mode and Effects Analysis
Field	Engineering
Published In	Volume 8, Issue 3, May-June 2026
Published On	2026-05-27

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Energy Consumption Analysis and Optimization in a Spinning Mill using IEM Tools

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