Case Study:

Improve Production and Reduce Energy Bills


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Customer Details
Steam usage in the ironing section of a garment manufacturing plant in Yangon, Myanmar.
Problems
High rejection rate due to stains on finished garments caused by water drip from irons.

Extra effort and time required for ironing in order to get quality finish.

Low quality steam supply.

Steam starvation in the ironing section.

High fuel consumption.
Objective
To optimise the ironing process for :

Increased productivity

Reduced rejection rate

Bringing down fuel cost

Improved work place safety
Solution
The Forbes Marshall team conducted a study of the process and following changes were made with products from Forbes Marshall as per recommendation

Replacement of :

Existing coal fired boiler with 1TPH rice husk fired boiler with air pre heater.

All existing traps with thermodynamic traps.


Installation of :

Pressure reducing station for stable steam pressure.

Moisture separators and strainers for all steam lines.

G-trap in each of the 80 irons.

Complete flash and condensate recovery system consisting of flash vessel, pressure powered pump packaged unit (PPPPU) and deaerator head for 100% CRF.

SteamMon steam flow meter to measure and monitor steam consumption.

Benefits
Boiler running at 82% efficiency with high S:F.

Optimum quality steam and quantity of steam.

Desired temperature attained quickly in all irons.

No high temperature condensate drainage.

High trap uptime Reduced rejection rate.

Increased productivity with better finish in 30% less man hours.

Enhanced operational safety.

Saving of US$1,770 per month in fuel bill.
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