Energy is one of the main cost factors in the textile industry. Especially in times of high energy price volatility, improving energy efficiency should be one of the main concerns of textile plants. In general, energy in the textile industry is mostly used in the forms of: electricity, as a common power source for machinery, cooling and temperature control systems, lighting, office equipment, etc.; oil as a fuel for boilers which generate steam; liquefied petroleum gas; coal; and city gas.

The textile industry is one of the major energy consuming industries and retains a record of the lowest efficiency in energy utilization. About 23% of energy is consumed in weaving, 34% in spinning, 38% in chemical processing and another 5% for miscellaneous purposes. In general, energy in the textile industry is mostly used in the form of: electricity, as a common power source for machinery, cooling & temperature control system, lighting, equipment etc.; oil as a full for boilers which generate steam, liquefied petroleum gas, coal. And this has made a pathway to the conservation of energy which can be affected through the process and machinery modifications and implementation of technological advancements relating to process optimization as well as the development of newer methods to meet the challenge of substantial energy saving in textile wet processing

There are various energy-efficiency opportunities in textile plants, many of which are cost-effective. However, even cost-effective options often are not implemented in textile plants due mainly to limited information on how to implement energy-efficiency measures, especially given the fact that the majority of textile plants are categorized as SMEs.


  • 15%

    Share of wet processing consumption of the total electrical energy mainly only for running the various processing machinery.

In the textile mill, electricity consumption is in the increasing trend, due to modernized machines and continuous usage of the equipment in inefficient operating parameters. The textile sector may be considered as one of the largest industrial sectors in India and at the same time, it is also one of the oldest sectors in the country. Even after a lot of technological development globally, most of the mills are using the same old technology. The energy cost is around 15%-20% over the production cost and it stands next to raw material cost. Hence now a day’s area of focus is towards energy consumption at load end and by optimizing the efficiency of the motor.

The main usage of electrical energy in the textile industry is in the manufacture of yam and cloth, amounting to nearly 3/4th or 4/5th of the total power requirement in a textile mill, whereas hardly 15 to 20% of electrical power is consumed for running various machines in textile wet processing.

  • One bath bleaching may enable to save around 70% electrical inputs.
  • Reduced number of ends / turns jiggers may help in saving around 20% electrical inputs.
  • Elimination of curing in printing saves 100% electrical inputs for curing step.
  • Combined drying - cum - curing in resin finishing save around 35% electrical inputs.
  • Use of high-efficiency motors in place of standard motors with the proper application will save 2 to 4%.
  • Replacement of undersize and oversize motors saving depending upon the percentage of loading on the motors.
  • Use of high-temperature grease according to insulation class of motors.