Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 32223
Energy Efficiency Approach to Reduce Costs of Ownership of Air Jet Weaving

Authors: Corrado Grassi, Achim Schröter, Yves Gloy, Thomas Gries


Air jet weaving is the most productive, but also the most energy consuming weaving method. Increasing energy costs and environmental impact are constantly a challenge for the manufacturers of weaving machines. Current technological developments concern with low energy costs, low environmental impact, high productivity, and constant product quality. The high degree of energy consumption of the method can be ascribed to the high need of compressed air. An energy efficiency method is applied to the air jet weaving technology. Such method identifies and classifies the main relevant energy consumers and processes from the exergy point of view and it leads to the identification of energy efficiency potentials during the weft insertion process. Starting from the design phase, energy efficiency is considered as the central requirement to be satisfied. The initial phase of the method consists of an analysis of the state of the art of the main weft insertion components in order to point out a prioritization of the high demanding energy components and processes. The identified major components are investigated to reduce the high demand of energy of the weft insertion process. During the interaction of the flow field coming from the relay nozzles within the profiled reed, only a minor part of the stream is really accelerating the weft yarn, hence resulting in large energy inefficiency. Different tools such as FEM analysis, CFD simulation models and experimental analysis are used in order to design a more energy efficient design of the involved components in the filling insertion. A different concept for the metal strip of the profiled reed is developed. The developed metal strip allows a reduction of the machine energy consumption. Based on a parametric and aerodynamic study, the designed reed transmits higher values of the flow power to the filling yarn. The innovative reed fulfills both the requirement of raising energy efficiency and the compliance with the weaving constraints.

Keywords: Air jet weaving, aerodynamic simulation, energy efficiency, experimental measurements, power costs, weft insertion.

Digital Object Identifier (DOI):

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1330


[1] S. Adanur, “Handbook of weaving” Boca Raton; London; New York: CRC; Taylor and Francis, 2001.
[2] Grassi, C., Schröter, A., Gloy, Y., and Gries, T. 2016. “Increasing the Energy Efficiency of Air Jet Weaving Based on a Novel Method to Exploit Energy Savings Potentials in Production Processes of the Textile Industry”, David Publishing Company, Journal of Environmental Science and Engineering B 5 (2016) 26-34, Vol 5, No 1B, 2016, doi:10.17265/2162-5263/2016.01.004.
[3] K. Erdem, Ç Emel, “Analysis of Energy Consumption in Woven Fabric Production.” Fibres and Textiles in Eastern Europe 2 (79): 14-20.
[4] International Textile Manufacturers Federation. 2012. Spinning/ Texturing/ Weaving/Knitting: “International Production Cost Comparison” 2012. Zürich: ITMF.
[5] Gloy, Y.-S.; Jungbecker, P.; Schenuit, H.; Gries, T.: „Energieeinsparung in der Luftweberei”, Abschlussbericht zum Forschungsvorhaben AiF 15599 N am Institut für Textiltechnik der RWTH Aachen, Aachen 2010.
[6] Holtermann, T.: “Methode zur Bewertung der Energieeffizienz von Produktionsprozessen der Textilindustrie” Aachen: Shaker, 2014; Zugl.: Aachen: Techn. Hochsch., Diss.; 2014.
[7] Grassi, C., Schröter, A., Gloy, Y., and Gries, T. 2015. “Reducing Environmental Impact in Air Jet Weaving Technology by Using a High Volume Low Pressure Relay Nozzle Concept based on Energy Efficiency as a Central Property.” Presented at the 50th Fiber Society’s, 2015 Fall Meeting, Raleigh, USA.
[8] Schröter, A., "Steigerung der Energieeffizienz des Luftdüsenwebverfahrens am Institut für Textiltechnik”. Förderverein Cetex Chemnitzer Textilmaschinenentwicklung e.V. (Hrsg.): Mehrwert durch Textiltechnik: Tagungsband zur 14. Chemnitzer Textiltechnik-Tagung; 13. und 14. Mai 2014. – Chemnitz.
[9] Holtermann, T.; Sasse, C.; Jessen, W.; Schröder, W.; Gries, T.: “Energieverbrauchsreduzierung durch verbesserte Ansteuerung von Stafettendüsen beim Luftdüsenweben” – EvereSt Abschlussbericht zum Forschungsvorhaben AiF 17408 N am Institut für Textiltechnik der RWTH Aachen, Aachen 2014.
[10] Jungbecker, P.A.: “Energieeinsparung an Luftwebmaschinen durch Strömungssimulation”, Aachen: Shaker, 2012; Zugl.: Aachen, Techn. Hochsch., Diss., 2012.
[11] Szabó, L.: “Weft Insertion trough open profile reed in air jet looms”, Annals of faculty Engineering Hunedoara – International Journal of Engineering, Tome X, year 2012, Fascicule 2 ISSN 1584 – 2665.
[12] Shintani, R., Okajima, A.: “Air Flow through a Weft Passage of Profile Reed in Air Jet Looms”, Journal of the Textile Machinery Society of Japan, Vol.54, No.1, T9 - T16 (2001-1), year 2001.
[13] Belforte, G., Mattiazzo, G., Testore, F., Visconte, C.: “Experimental investigation on air-jet loom sub-nozzles for weft yarn insertion”, Textile Research Journal 81 (8) 791-797.
[14] Neugebauer, R.: “Approach for the development of energy efficiency machine tools”, Conference on Supervising and Diagnostics of Machine Systems. Wroclaw, Poland, Karpacz: s.n., 2010.