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Retrofits & Accessories
for
Textile Process Houses
from
A.T.E. Enterprises Private Limited

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Retrofits
&
Accessories
Save
Cost
Improve
Productivity
Improve
Quality

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Critical challenges of Indian processing units
Productivity
Quality
High cost of capital
Rising energy costs
Water scarcity
Critical
challenges
faced by Indian
processing
units

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Retrofits and utilities from A.T.E.
A range of retrofits
and utilities that will
result in :
Enormous saving in energy
Improved productivity
Improved quality
 with a substantially low investment
 and fastest ROI!

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Retrofits
&
Accessories
Save
Cost
Improve
Productivity
Improve
Quality
Improve
Quality
Improve
Productivity

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Mahlo Atmoset SMT-12 is an online
moisture control and monitoring
system, that controls the steam input
in drying cylinders by optimising the
drying process, thus saving heat
energy (30%-50% saving in steam
can be achieved) and results with
consistent quality output.
Payback in just 8 months!!!
Reference: Alok (Vapi), Auro (Baddi), Welspun (Anjar), GHCL (Bhilad)
Saveenergy–Savecost
Steam consumed per kg. of fabric
processed on drying range (without
Atmoset SMT-12)
1.2 kg
Steam saved per kg. of fabric
processed (considering just 25%
steam saving with Atmoset SMT-12)
0.25 kg
So, steam saved after processing 21
MT (or 80,000 meters) of fabric per
day
0.25 × 21000
= 5250 kg
Considering 25 days working per
month, steam saved per month
1,31,250
kg/month
Cost of steam saved per year*
Rs.
25,20,000
Cost of Mahlo Atmoset SMT-12: Rs.16,25,000**
So, ROI = 7.74 months ~ 8 months
(*Cost of steam considered @ Rs.1.6/kg)
Mahlo - Atmoset SMT 12
**Prices of equipment are indicative and are subject to change

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Payback in just 2 months!!!
Reference:
The shell and tube system
recovers heat energy from waste
water and uses it to heat fresh
water, while maintaining
constant process water
temperature by means of a PLC
attached to the system.
Input parameters Output parameters
Waste water 20 m3
/hr Fresh water inflow: 20 m3
/hr
Wastewater @ 80˚C
cooled to 41.15˚C
Fresh water @ 25˚C; heated up
to 63.57˚C
Thermal efficiency: 886.1kW
Fuel used: Firewood (calorific value of 3000 kcal/kg)
Cost of fuel: Rs. 3/kg
Total working hours per year: 6000
Fuel saving per year: 2177 MT
Cost of fuel saved: Rs. 65,31,900
Cost of Luwa water to water heat recovery system =
Rs. 8,50,000**
So, ROI = 1.56 months ~ 2 months*
Saveenergy–SavecostLuwa - water to water heat recovery system
**Prices of equipment are indicative and are subject to change
N.B: Performance depends on constancy of input parameters and maintenance

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Payback in just 15 months!!!
Reference: Ruby (Khopoli), Oswal F.M. Hammerle (Kolhapur), GHCL (Bhilad)
A retrofit for the Osthoff singeing
machine for objective measurement of
the hairiness of the fabric for proper
control of the singeing process by
regulating gas intensity as per the
fabric hairiness, resulting in uniform
hairiness across the batch. Regulation
of gas intensity also results in saving of
gas.
Without
online
hairiness
tester
With online
hairiness
tester
Consumption of gas in kg/hour 15 11.5
Cost of gas in Rs./hour 945 724.5
Cost of gas in Rs./day 18,900 14,490
Cost of gas in Rs./month 4,72,500 3,62,250
Cost of gas in Rs./annum 56,70,000 43,47,000
Net savings (Rs./annum) 13,23,000
Cost of online hairiness system: Rs.1,625,000**
Cost of propane considered @ Rs. 63/kg
Working hours considered @ 20/day
Working days considered @ 25 days/month
Improvedquality&costsavingsOsthoff - online hairiness tester
**Prices of equipment are indicative and are subject to change

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A robust, third generation retrofit, made
of metal foam for the pre-dryer installed
on the CDR to reduce the moisture on
the fabric before it enters the hot flue, to
avoid migration of dyestuff. Varying gas
intensity with actual temperature
requirements (in the range of 600 to
800 ˚C) results in saving in gas to the
extent of 25-30% as compared to
ceramic pre-dryers.
Saveenergy–Savecost
Payback in 50.4 months
Monforts - infrared pre-dryer for CDR
**Prices of equipment are indicative and are subject to change
Reference: Arvind (Ahmedabad), Auro (Baddi), Alok (Vapi)
Parameter Old New
Consumption of gas in kg/hour 33 kg 20 kg
Cost of gas in Rs./hour Rs. 2,079 Rs. 1,260
Cost of gas in Rs./day Rs. 41,580 Rs. 25,200
Cost of gas in Rs./month 1,039,500 630,000
Cost of gas in Rs./annum 12,474,000 7,560,000
Net savings in Rs. 4,914,000
Cost of infrared pre-dryer for CDR: € 295,000 or Rs. 20,650,000**
Cost of propane considered: Rs. 63/kg
Working hours considered: 20/day
Working days considered: 25/month
Return on investment: 50.4 months

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Retrofits
&
Accessories
Save
Cost
Improve
Productivity
Improve
Quality
Improve
Quality
Save
Cost

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Improveproductivity–Improveprofit
Description
A residual moisture
measurement
instrument for drying
ranges that controls
the degree of dryness
of the product by
means of dryer speed
based on the residual
moisture
Benefits
 Improved productivity
 Energy optimisation
 Optimal residual
moisture for
subsequent
processing
References
Alok (Vapi), Oswal
Hammerle
(Kolhapur),
Vardhman (Bhopal),
Auro (Baddi), Birla
Century (Bharuch)
Mahlo textometer RMS can be used in stenter, pad steam and pad
dry, and CBR.
Mahlo - textometer RMS

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Description
This advanced textile
digital metal detector is
highly sensitive to all
magnetic and non-
magnetic metals. The
compact and robust
construction of this metal
detector with plug-and-
play settings ensures a
high degree of protection
(IP 65 – RC version)
Benefits
 Highly reliable at a
wide range of speeds,
as high as 600
m/minute
 Can detect ferrous and
non-ferrous metal as
small as 0.8 mm.
 Prevents damage to
rubber rollers and
fabric
 Higher machine uptime
 Higher productivity
 Higher safety
 Better quality output
References
Alok (Vapi), Oswal
Hammerle (Kolhapur),
Vardhman (Bhopal),
Auro (Baddi), Birla
Century (Bharuch),
Jakharia (Boisar),
Mandhana (Boisar),
etc.
Improveproductivity–Improveprofit
CEIA metal detectors can be used in shearing, calendar, shrinking
singeing machines, dye padder and CBR
CEIA - bar metal detector

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Description
The THS 21 conveyor
satisfies the most
stringent requirements for
functionality, compact
construction, accuracy
and reliability of response
in dealing with accidental
metallic contamination of
products
Benefits
 Very high sensitivity to
ferrous and all
magnetic metals
 Detection sensitivity
compliant with the
textile industry
Standards
 Digitally-adjustable belt
speed
 Structure and metal
detector in AISI 316L
stainless steel
 High flexibility: all parts
completely reversible
and modular
References
Welspun (Anjar),
SEL (Punjab), Trident
(Budhni)
Improveproductivity–Improveprofit
CEIA metal detectors can be used in a multitude of textile related
applications
CEIA - conveyor metal detector

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Description
Comprising of Ecomat
AML, textometer RMS
and Permaset VMT, The
ecopac EMC-12 monitors
and controls exhaust air
moisture, residual
moisture, and fabric heat
setting temperature
respectively, resulting in
improved productivity and
energy optimisation
Benefits
 Improved productivity
 Energy optimisation up
to 16%
 Consistent quality
References
Alok (Vapi), Oswal
Hammerle (Kolhapur),
Vardhman (Bhopal),
Auro (Baddi), Birla
Century (Bharuch)
Improveproductivity–Improveprofit
Mahlo ecopac EMC-12 can be used in stenters
Mahlo - ecopac EMC-12

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Description
An innovative
technology which is CE
certified and available
in different capacities,
to provide moisture-free
compressed air to
pneumatic systems on
various machines.
Compressed air cools
the incoming air and
separates the moisture
via a timer-controlled
electronic drainage wall
Benefits
 Higher machine uptime
 Higher productivity
 Long life of pneumatic
systems
 Less maintenance
References
Manan Cotsyn (Boisar),
Valiant (Boisar), Sutlej
(Bhilad)
Improveproductivity–ImproveprofitAdvance Cooling - compressed air dryer

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Description
CE-certified and
available in different
capacities, panel ACs
help protect costly
electronic equipment
from the heat generated
by drives in the
electrical panel as well
as dust and humidity
Benefits
 Higher machine uptime
 Higher productivity
 Long life of electronics
 Less maintenance
References
Alok (Vapi), Ruby
(Khopoli), BRFL
(Boisar), Kothari
Exports (Kolkata),
Khosla (Mumbai), etc.
Improveproductivity–ImproveprofitAdvance Cooling - panel air conditioner

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Description
A unique system that is
CE-certified and
available in different
capacities to maintain
constant temperature of
the dye liquor and
chemicals in the trough.
This water chiller
circulates chilled water
around the walls of the
trough to maintain its
temperature at a
desired level
Benefits
 Improved productivity
 Evenly dyed fabric
 Reduced re-dyeing
 Minimum tonal and
shade variations in the
dyed fabric
References
Ruby (Khopoli), Auro
(Baddi), Raymond
UCO (Yavatmal)
Improveproductivity–ImproveprofitAdvance Cooling - water & oil chiller

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Retrofits
&
Accessories
Save
Cost
Improve
Productivity
Improve
Quality
Save
Cost
Improve
Productivity

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Improvedquality–ImproveprofitCorino - beating & brushing systems
Benefits
 Improves productivity
 Improves quality
 Energy optimisation
References
Alok (Vapi), Oswal Hammerle (Kolhapur),
Vardhman (Bhopal), Auro (Baddi), Birla
Century (Bharuch)
Description
A compact unit with the provision to
attach different brushing or beating
systems.
Used in singeing machines,
CBRs, and printing machines

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Improvedquality–ImproveprofitA.T.E. - rotary drum filter
Benefits
 Improves productivity
 Improves quality
 Reduces maintenance
References
Alok (Vapi), Indocount (Kolhapur),
Himatsingka (Hasan), Birla Century
(Bharuch), GHCL (Bhilad), Aarvee Denim
(Ahmedabad), Welspun (Anjar)
Description
A compact unit with a brushing system
for removal of fluff from drums without
using water
Used in singeing / desizing
systems, CBRs, and CRP (Caustic
Recovery Plant)

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Improvedquality–ImproveprofitA.T.E. - screen filter
Benefits
 Reduces labour cost
 Less maintenance
 Hassle-free system
References
Chenab Textile (Kathua)
Mandhana (Boisar)
Description
A compact unit with screen type
brushing system for removal and
collection of fluff
Used in ETP inlet at preliminary
treatment stage and various
drainage outlet as well

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Improvedquality–ImproveprofitRotovac - online dust & lint removal system
Benefits
 Reduces labour cost
 Less maintenance
 Hassle-free system
References
Arvind (Ahmedabad), NSL Textiles
(Hyderabad), BRFL (Boisar)
Description
A compact unit with a spring-type
brushing system for automatic
removal and collection of fluff
Used in rotary and flat bed
printing machines

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Improvedquality–ImproveprofitMonforts - chambers for stenter, pad dry
Benefits
Improves productivity at low investment
References
India Dyeing (Erode), Alok (Vapi), BJ
Textiles (Naidupet)
Description
Additional chamber with running
stenters, hot flues

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Improvedquality–ImproveprofitMontimac - rail sewing machine
Benefits
 Reduces wastage of fabric
 Improves fabric & stitch quality
References
BRFL (Boisar), Indocount (Kolhapur),
Shreeji Lifestyle (Dombivali)
Description
Rail sewing machine for head to
head stitching of fabric edges before
batching

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Improvedquality–ImproveprofitCorino - guidance system for digital printing
machine
Benefits
 Perfect feeding and winding of fabric
with uniform tension
 Improves printing quality
References
Shreeji Lifestyle (Dombivali)
Description
Compact unit that ensures uniform &
tensionless feeding of fabric to
printing machine

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Improvedquality–ImproveprofitMonforts - eco applicator
Benefits
 Improves fabric quality
 Reduces energy costs for drying /
increases speed
References
Not yet sold in India; numerous
installations abroad
References available on request
Description
For controlled application of
chemicals (softener, hydrophobic,
hydrophilic, stain repellants, etc)

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Improvedquality–ImproveprofitDunline - endless rubber shrinking belts
Benefits
 Uniform performance throughout the
life of the belt
 No material defect
 Improves fabric quality
References
Alok (Vapi), Raymond (Kolhapur), Arvind
(Ahmedabad), JCT (Pagoda), RMB
Denim (Surat), Century Denim (Indore),
etc.
Description
For fabric shrinking on shrinking
ranges

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Improvedquality–ImproveprofitDunline - endless felts
Benefits
 Designed to offer uniform performance
throughout the life of the felt; no
material defects
 Improves fabric quality
References
Jindal Worldwide (Ahmedabad), Bhaskar
Denim (Bhopal)
Description
For drying & giving feel to fabric
used on palmer drum of sanforizer,
relax dryer, printing dryer

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Improvedquality–ImproveprofitDunline - accessories
Benefits
 Maintain and increase longevity of
the belt & felt
References
BRFL (Tarapur), Mandhana (Tarapur),
Oswal Denim (Lalru and Bhopal), Nahar
(Lalru), Bhaskar Industries (Bhopal),
Indocount (Kolhapur)
Description
 Topline belt safe compound
 Topline safe wash
 Topline belt lube
 Topline paralel gauge
 Topline surface contact thernmom

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Improvedquality–ImproveprofitMAG - textile testing instruments
Benefits
 Quality assurance
 Support customization
 Calibration & test certification
 Provision of AMC and OMC
References
E I Dupont India (Hyderabad), Alok
(Silvassa), Morajee (Nagpur), Alps
(Ghaziabad), Grasim (Bhiwani), Shree
Sidvinayak Texco (Ludhiana), Shree Balaji
(Ludhiana), Pratap (Ambala), Ahuja Cotspin
(Punjab), Garg Acrylics (Punjab), KPR
(Tamil Nadu), Keshar Multi Yarns (Kolkata),
Vishnu Cotton Mills (Kolkata)
Description
High quality textile testing instruments at
affordable cost

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Improvedquality–ImproveprofitValence - static discharge bars
Benefits
 Improves safety
 Helps to improve productivity
 Helps to improve quality
References
Nahar (Lalru), Tex n Nets (Gurgaon), Jain
Textiles (Gurgaon), Surya Processors
(Ghaziabad), Alps (Ghaziabad), Kudu Knits
(Ludhiana)
Description
Compact, sturdy and reliable static
discharge bars to eliminate electrostatic
charge on moving parts

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Improvedquality–ImproveprofitA.T.E. - material handling system
Benefits
 Low effort transport system
 Suitable for heavy loads
 Trouble-free working
References
NSL (Guntur), Birla Century (Bharuch),
K G Denim (Mettupalayam), D Décor
(Tarapur), Premier Fine Linens
(Perundurai), Trident (Budhni) and
Himatsingka Linens (Hasan), Welspun
(Anjar)
Description
Supply of all types of material handling
equipment to store and move textile
substrates from one machine to another

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Improvedquality–ImproveprofitA.T.E. - lubricants and greases
Benefits
 Resists hydrocarbon washout/dilution
 High load carrying capacity
 Reduced sludge and deposit formation
 Excellent oxidative and thermal stability
 Low friction and less power
consumption
References
Description
High quality speciality lubricants which
can perform under extreme conditions
of speed, temperature & load. Different
purpose grease & oil, aerosol sprays for
wet and dry applications for trouble free
operation of machines for longer
duration
Mandhana (Boisar), Alok (Vapi), BRFL
(Boisar), Valiant Glass (Boisar), Mudra
Lifestyle (Boisar), Ruby (Khopoli), Arvind
(Ahmedabad), Premier (Bengaluru),
Himatsingka Linens (Hasan), Vardhman
(Budhni), Nahar (Lalru), etc…

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Improvedquality–ImproveprofitA.T.E. - textile automation control systems
Benefits
 Improves the performance of old
machines
 Hassle free operation
 Improves production of machines
 Reduces operation time
 Reduces operation cost
References
Welspun Syntex (Silvassa), Bhaskar
Denim (Bhopal), Balkrishna Synthetic
(Tarapur), Indorama Synthetic (Nagpur),
Arvind (Ahmedabad), JCT (Phagwara),
Premier (Coimbatore)
Description
Complete, customized retrofit and
automation solutions for the textile
industry

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