Here are 12 low-carbon solutions we are implementing in our factories for fabric production:

1. Optimize the ring diameter of the ring spinning machine 

Objective: Reduce energy consumption of the spinning machine

Principle: Reducing the ring diameter can decrease the weight of the yarn package and rotational resistance, thus reducing motor load.

Plan: Select the minimum feasible ring diameter based on the yarn count (e.g., replace 40cm with 38cm/36cm) and adjust the machine

speed to compensate for capacity changes.

2. Install a variable frequency drive to control the humidification system fan 

Objective: Reduce energy consumption of the humidification system

Principle: Adjust the fan speed to match actual humidity requirements, avoiding energy waste due to fixed speeds.

Plan: Install a variable frequency drive (VFD) on the humidification system fan motor to dynamically adjust the flow rate based

on sensor feedback.

3. Application of counterflow washing technology

Objective: Reduce water and steam consumption in wet processes

Principle: Washing water flows backward from the last tank to the previous tank, using residual heat and chemicals stepwise.

Plan: Retrofit the water flow direction of the continuous washing machine to adopt a counterflow washing design, reducing fresh

water and heating requirements.

4. Cold-rolled batch dyeing system

Objective: Reduce dyeing energy consumption and chemical usage

Principle: Solidification of dye at low temperatures through prolonged stacking avoids high-temperature steam consumption.

Plan: Use cold-rolled batch equipment instead of traditional high-temperature dyeing machines, optimizing the chemical formula and stacking time.

5. Recover residual heat from dyeing wastewater

Objective: Reduce thermal energy waste

Principle: Use a plate heat exchanger to recover heat from high-temperature wastewater to preheat fresh or process water.

Plan: Install a heat exchanger at the dyeing machine outlet to transfer wastewater heat to the incoming water pipeline.

6. Control humidity of exhaust gases in the stretching machine

Objective: Reduce drying energy consumption

Principle: Real-time monitoring of exhaust gas humidity with sensors can reduce excessive air heating.

Plan: Install an automatic exhaust control system to dynamically adjust the fan speed and exhaust volume.

7. Repair leakage in the compressed air system

Objective: Reduce energy consumption of compressed air

Principle: Fixing leaks can lower the load and operating time of the compressor.

Plan: Regularly use ultrasonic detectors to inspect and identify leaks, replacing aging pipes and fittings.

8. Replace conventional motors with high-efficiency motors

Objective: Improve motor system energy efficiency

Principle: High-efficiency motors reduce internal losses and enhance energy conversion efficiency through optimized design.

Plan: Prioritize the replacement of motors (such as pumps and fans) that operate over 2,000 hours annually with IE3/IE4 high-efficiency

models.

9.Recover condensate from the steam system 

Objective: Reduce fuel consumption of the boiler

Principle: High-temperature condensate recovery can be directly used for boiler makeup water, lowering heating energy consumption.

Plan: Install condensate recovery pipelines and tanks at the outlet of equipment such as drying drums and dyeing machines.

10.Replace steam drying with radio frequency drying technology

Objective: Reduce energy consumption in yarn drying

Principle: Radio frequency technology generates heat through molecular friction, directly acting on moisture and avoiding heat loss to the

environment.

Plan: Employ radio frequency dryers in the drying process of yarn, replacing traditional steam heating systems.

11. Automated chemical metering and distribution system

Objective: Reduce chemical waste and wastewater treatment energy consumption

Principle: Precise control of chemical usage avoids overuse and repeated rinsing.

Plan: Install automated dispensing equipment integrated with flow meters and PLC control programs.

12. Upgrade the factory lighting system

Objective: Reduce lighting energy consumption

Principle: High-efficiency fixtures (like LED or T8 fluorescent lights) and smart controls minimize ineffective lighting time.

Plan: Replace traditional T12 fluorescent lights with LED fixtures and install light and motion sensors for time-controlled operation.