Journal of Textile Science and Technology, 2023, 9, 69-83

https://www.scirp.org/journal/jtst
ISSN Online: 2379-1551
ISSN Print: 2379-1543

Minimization of Air Consumption and

Potential Savings of Textile Denim Fabric
Manufacturing Process

Md. Enamul Haque1*, Md. Bokthier Rahman1, Waliul Kafi2, Md. Suja Uddin Kaiser1, Abhijit Dey2

Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh

1

Bangladesh University of Textiles (BUTEX), Dhaka, Bangladesh

2

How to cite this paper: Haque, Md.E., Abstract

Rahman, Md.B., Kafi, W., Kaiser, Md.S.U.
and Dey, A. (2023) Minimization of Air One of the most important aspects of Bangladesh’s textile industry is denim.
Consumption and Potential Savings of Tex- Bangladesh now has a new opportunity thanks to the global demand for de-
tile Denim Fabric Manufacturing Process.
nim among fashion industry professionals. Entrepreneurs from Bangladesh
Journal of Textile Science and Technology,
9, 69-83.
provide denim products to well-known international merchants all over the
https://doi.org/10.4236/jtst.2023.91005 world. The worldwide denim market is predicted to expand by roughly 8%
through the year 2020. We must raise the standard of denim if we are to keep
Received: December 19, 2022
up with the expanding industry. In contrast to projectile and rapier systems,
Accepted: February 24, 2023
Published: February 27, 2023 air-jet weaving machines nowadays can weave practically all types of yarns
without any issues and at higher rates. Due to this, air-jet looms are an excel-
Copyright © 2023 by author(s) and lent substitute for other weft insertion techniques. This kind of device still has
Scientific Research Publishing Inc.
one significant flaw, though, and that is the enormous power consumption
This work is licensed under the Creative
Commons Attribution International
brought on by the creation of compressed air. Researchers and manufacturers
License (CC BY 4.0). of air-jet looms have therefore worked very hard to find a solution to this is-
http://creativecommons.org/licenses/by/4.0/ sue and achieve a huge reduction in air consumption without compromising
Open Access loom performance or fabric quality. Therefore, the purpose of this project is
to look into ways to decrease air consumption and reduce auxiliary selvedge
waste without any decrease in loom performance and fabric quality on exist-
ing air-jet weaving looms which reduce the manufacturing costs with process
improvement. Just updating the air pressure allowed a weaving mill to reduce
air usage by 11 cfm. So, with just almost no cost, a company with 100 looms
could save $0.15 M each year, on compressed air. Two new methods for de-
creasing process costs on air jet looms have also been developed by this
project work.

Keywords
Denim, Woven Textiles, Weaving Machine, Air Consumption,

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Md. E. Haque et al.

Cost Reduction, Waste Reduction, Potential Savings

1. Introduction
One of the most successful and prolific weaving machines in the textile business
is the Air Jet. Air-jet weaving machines have a higher manufacturing cost than
Rapier and Projectile weaving machines due to the addition of compressed air
costs. This results in energy problems. As a result, numerous manufacturers and
researchers are constantly trying to increase the effectiveness of air jet weft in-
sertion. The goal is to look at how much air is used during air jet weaving in in-
dustrial settings. The distance between the compressor and the weaving ma-
chine, the number of joints, unneeded valve openings, pipe leaks, etc. are the
main causes of the difference in air-jet consumption on air-jet weaving ma-
chines, which results in an increase in compressed air consumption. Despite
their high production speeds, this is making air jets less desirable due to the
problem with energy costs.
Despite the fact that practically all machines come from the same manufac-
turer and model, air usage differs. Before being used in a machine, the air is
filtered and compressed. The manufacturing cost of air-jet weaving increases
as a result of substantial compressed air consumption and increased electricity
costs.
The air jet generates the forces needed to move and accelerate the weft yarn.
These pressures need to be greater than the sum of the forces of the yarn bob-
bin's resistance, inertia, and reserve system. Weft yarn characteristics and the
physical parameters of the airflow are taken into account while defining the car-
rier and resistive force characteristics. Due to their characteristics, such as tur-
bulent and laminar airflow, yarn diameter, linear density (count), and elasticity,
air velocity, and yarn structures have intricate interrelations.
Another part of the work reported in this project is an account of wastes gen-
erated in air-jet weaving mills. The wastes were mainly divided into two catego-
ries: 1) wastes related only to the warp, such as gera cones, knotting waste, gait-
ing/tying-in, loom setting, beam residue after sizing and weaving, warping, in
the sizing zone, and the warp yarns in the auxiliary selvedge, etc.; and 2) wastes
related only to the weft, such as cut fringe, defective cones, waste due to loom
set. This work includes gathering information from the air jet weaving mills on
auxiliary selvedge warp waste. Following that, the amounts of waste were ex-
pressed as percentages of the total amount of warp waste.

2. Project Work Area

In my organization, there are so many departments from raw materials to final
inspection such as Materials Testing, Yarn Processing, Fabric Manufacturing,
Fabric Finishing, Fabric Dyeing, Fabric Washing, Fabric Testing, and Fabric In-

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 Md. E. Haque et al.

spection. Among these departments, I want to complete my project work in the

Fabric Manufacturing/Weaving section. The purpose of this project work is to
reduce fabric-making process costs by updating machine materials and process
routes. Various factors are involved to reduce process costs but I am working
with two prime factors air consumption reduction and raw-materials optimiza-
tion.
Firstly, air consumption reduction, there are more than 250 air-jet weaving
machines which is the major consumption of compressed air. The cost of pro-
ducing compressed air and maintenance of the compressor is very high which
can impact on the product cost. We can reduce the utilization of compressed air
by updating some components which are shown in this project work.
Secondly, waste reduction is an important factor to minimize cost reduction
and potential savings. By applying some settings, we can retrench the waste and
also save the raw materials. This will help us to decrease the ultimate product
cost. We will complete this task that how can we reduce waste by optimizing raw
materials in our project work.

3. Objective
3.1. Broad Objective
This report’s major goal is to lower process costs through the modernization
of machine components and workflows. There are many elements that affect
process costs, but I am focusing on the main ones: decreased air use and im-
proved raw material utilization. This report, which demonstrates the assignment
I was given during my research work, is presented as an experiential report. My
results in this report are consistent with what I discovered throughout my re-
search.

3.2. Specific Objective

• To reduce the compressed air consumption cost
• To calculate the volume of air used in the insertion area
• To minimize the air consumption by updating machine materials
• To reduce the waste by raw materials optimization

4. Methodology
In a cotton twill fabric like denim, the weft weaves underneath two or more
warp threads. Weft threads in a denim fabric are left white while the warp
threads are indigo colored. Due to its remarkable durability, denim was first uti-
lized for work garments.
One of the successful and highly productive shuttle-less weaving machines in
the textile industry is the air-jet machine. On an air jet loom, an air-jet is a de-
vice that uses high air pressure to enter the weft yarn. Prior to being used on a
loom, the air is compressed and purified. The manufacturing cost of air-jet
weaving is higher than that of other weaving technologies due to the large com-

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Md. E. Haque et al.

pressed air consumption and added compressor electricity expense. This is the
reason why, despite their high production speeds, air-jet weaving is becoming
less popular where energy costs are an issue [1]. According to how the weft is
inserted, weaving machines are divided into four groups: shuttle, projectile,
rapier, and jet (also known as air and water jet) looms. The air jet weaving sys-
tem is frequently used because it produces goods more quickly than other sys-
tems. Low air consumption will be achieved without sacrificing product quality
by updating machine components and maintaining the air pressure of the air jet
loom along the main valve & relay valve drive time. By enhancing some relay
nozzle and selvedge pattern parameters, the primary goal is to reduce air con-
sumption. In order to achieve this, the weavers will alter the relay nozzle type
throughout the course of the study [2]. Experiments regarding relay nozzle di-
ameter and waste reduction by raw materials optimization will conduct on the
Tsudakoma loom which originated in Japan. This is a very high-speed loom and
the maximum speed is 2500 RPM but we can use ZAX 9100 model due to our
availability which speed is around 850 RPM. For denim fabric, we need to run
the machine at around 800 RPM because of the coarser count of yarn is used in
this type of fabric. Compressed air is one of the key energy-consuming utilities
in any sector and is sometimes referred to as the “4th Utility” (after electricity,
water, and steam). Despite being one of the most expensive utilities, many con-
sumers find it challenging to calculate their cost per cfm. The first thing to real-
ize is that compressed air uses three to four times as much energy as electricity.
However, compressed air's extremely adaptable nature, it improves the produc-
tivity and safety of many industrial processes [3]. Relay nozzles are the main fo-
cus of the study because they use 80% of compressed air. I think we can save
more than 15% of compressed air through this project experiment. In addition
to this, we can save a lot of amounts by raw materials optimization and con-
struction & process improvement. I can’t say the exact value but I assume that it
will be 10% more profitable than the previous one.
Process Flow Chart of Denim Textile:

5. Findings
5.1. Air Consumption Reduction
5.1.1. Experimental Details
The main function of compressed air in an air-jet weaving machine is to insert

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 Md. E. Haque et al.

the weft by using the main nozzle and relay nozzle to complete the weave struc-
ture. Here the main nozzle is used to hold the weft yarn and pass it into the pro-
file reed. There are fifteen sets of sub nozzle/relay nozzle attached with profile
reed to complete the insertion system. A schematic of air-jet weaving using a
multiple nozzle system and a profiled reed, the most popular design on the
market, is shown in Figure 1 [4].
The filling feeder draws yarn from a filling supply package, and a stopper
measure each pick for the filling insertion. The filling is supplied into the reed
tunnel by the relay and primary nozzles once the stopper releases the filler yarn.
While the high air velocity across the weave shed is provided by the relay noz-
zles, the initial acceleration is provided by the sub and main nozzle combination.
The filler yarn and warp are separated by profiled reed, which also guides the air.
After the yarn has been inserted all the way, it is cut with a cutter [5].
In this experiment, we used two types of sub nozzles named energy savings
nozzle which is made by our own requirements, and regular nozzle which is
provided with the machine. We used these nozzles in 20 machines and calcu-
lated our experimental data on saving compressed air.

5.1.2. Relay Nozzle Hole Diameter

The diameter of a regular nozzle hole is 1.4 mm and it is straight to the reed pro-
file. On the other hand, the diameter of energy saving nozzle is 1 mm and it’s
slightly angled to the insertion direction which is shown in Figure 2 and Figure
3 [6]. The main difference between these two types of nozzle is diameter, angle
direction, and also the cost of energy savings nozzle is lower than a regular one.

5.1.3. Machine and Fabric Parameter

For both types of nozzles, we preserved identical machine and fabric specifications

Figure 1. The weft insertion system of air-jet weaving machine.

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Md. E. Haque et al.

Figure 2. Regular nozzle & energy savings nozzle.

Figure 3. Detailed view of relay nozzles on loom.

in this section which is shown in Table 1. Here, we alternately employed these

two different nozzles in the same machine while collecting data using a CFM
(Cubic Feet per Minute) meter.

5.1.4. Experimental Data

For this experimental work, we have taken five different fabric construction and

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 Md. E. Haque et al.

Table 1. Machine & fabric parameter for various relay nozzle.

Parameters Regular Nozzle Energy Saving Nozzle

Machine Brand TSUDAKOMA ZAX9100 TSUDAKOMA ZAX9100

Machine Speed (RPM) 750 750

Machine width (cm) 190 190

Reed Count (Dent/Inch) 23.5 23.5

Fabric Weave 3/1 RHT 3/1 RHT

8RSL + 9RSL × 8RSL + 9RSL ×

10L70D/63 × 48 10L70D/63 × 48

7OE × 9OE/66 × 38 7OE × 9OE/66 × 38

Fabric Construction
20Ry × 150L40D/110 × 64 20Ry × 150L40D/110 × 64

7OE × 10OE/63 × 35 7OE × 10OE/63 × 35

7OE × 8L40D/55 × 43 7OE × 8L40D/55 × 43

Total number of
20 20
Loom Used

Total Nozzle used per Loom 30 30

Relay Nozzle
1.4 1
Diameter (mm)

Cost of Relay Nozzle Set 1500 1000

mounted them on 20 machines. In Table 2, we have organized our data which

got from machine. Firstly, we checked the machine thoroughly and run this with
a regular nozzle. In the meantime, we measured the airflow with a CFM meter
and have taken the exact data. Secondly, we have replaced these regular nozzles
with energy savings nozzles for the same machine of the same fabric construc-
tion. Then we have taken data from the energy savings nozzle and compared it
with the regular nozzle. We have adopted data on air consumption more than
five times and recorded the average data in the datasheet. During this work, the
electrical and mechanical setting of these machines was the same.
CFM—The most popular unit of measurement for airflow is CFM or cubic
feet per minute. Square units are used to measure areas (like square feet). Cubic
units are used to measure volumes (such as the volume of air in a room), and
CFM measures how many cubic feet may be exchanged or transported every
minute shown in Figure 4 [7]. [1 CFM is 1.699 m3/h] [8].
From the experimental data, we see that the utilization of compressed has re-
duced due to using of energy savings nozzle for every construction of the fa-
bric and also show that the reduction percentage is higher. No significant ef-
fect on machine efficiency was observed due to the relay nozzle hole diameter
change.

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Md. E. Haque et al.

Table 2. Machine efficiency & CFM data from running machine.

Machine Efficiency (%) Total CFM

Machine Fabric CFM Reduction
No Construction Regular Energy Saving Regular Energy Saving Reduction (%)
Nozzle Nozzle Nozzle Nozzle

8RSL + 9RSL ×
1040 95.1 96.21 61.38 45.35 16.03 26.12
10L70D/63×48

8RSL + 9RSL ×
1043 95.31 95.81 62.79 47.21 15.58 24.81
10L70D/63 × 48

8RSL + 9RSL ×
1062 94.25 93.31 61.14 44.31 16.83 27.53
10L70D/63 × 48

8RSL + 9RSL ×
1068 96.98 96.21 62.29 43.94 18.35 29.46
10L70D/63 × 48

1113 7OE × 9OE/66 × 38 97.32 95.65 63.63 54.35 9.28 14.58

1115 7OE × 9OE/66 × 38 95.13 95.81 64.98 55.81 9.17 14.11
1117 7OE × 9OE/66 × 38 93.64 94.78 63.17 53.81 9.36 14.82
1122 7OE × 9OE/66 × 38 95.87 96.5 62.24 52.12 10.12 16.26
1042 20Ry × 150L40D/110 × 64 98.25 100 77.28 68.19 9.09 11.76
1045 20Ry × 150L40D/110 × 64 99.15 98.15 78.94 67.25 11.69 14.81
1092 20Ry × 150L40D/110 × 64 99 98.35 77.63 69.31 8.32 10.72
1093 20Ry × 150L40D/110 × 64 100 100 77.13 70.21 6.92 8.97
1041 7OE × 10OE/63 × 35 96.75 96.1 66.74 60.98 5.76 8.63
1046 7OE × 10OE/63 × 35 95.55 95.25 67.45 59.39 8.06 11.95
1057 7OE × 10OE/63 × 35 92.21 95.36 66.38 59.87 6.51 9.81
1077 7OE × 10OE/63 × 35 95.89 96.45 67.41 59.97 7.44 11.04
1105 7OE × 8L40D/55 × 43 90.25 93.65 64.94 56.81 8.13 12.52
1125 7OE × 8L40D/55 × 43 98.15 97.85 63.21 54.18 9.03 14.29
1126 7OE × 8L40D/55 × 43 97.65 96.35 64.36 55.47 8.89 13.81
1130 7OE × 8L40D/55 × 43 95.35 95.15 64.29 56.91 7.38 11.48

CFM = Cubic feet per minute.

Figure 4. CFM meter for air consumption measurement.

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 Md. E. Haque et al.

5.1.5. Cost Calculation

From Table 2, we see that the average CFM for a regular nozzle is 66.87 and the
energy savings nozzle is 56.78. So, the average air consumption reduction is
10.097 CFM. We can calculate it as a percentage and that value is 15.09%.
We can also show it as fabric construction-wise and get our desired savings
value from Table 3.
For Regular Nozzle:
Here, the Average CFM is 66.87 & Efficiency is 96.08%.
So, We can calculate it to hours, days, and finally for one year.
Now, CFH (Cubic Feet per Hour) = CFM × 60 = 66.87 × 60 = 4012.20.
So, for 24 hours (1 day) = 4012.20 × 24 × 0.96 = 92441.08.
∴ Compressed air consumption per day for 1 machine is 92441.08 cubic feet.
Now, let the approximate value of compressed air generate cost including in-
vestment and maintenance cost which is $0.30 per 1000 cubic feet [9].
So, total cost of compressed air for 1 machine per day is = $(92441.08 ×
0.30)/1000 ≅ $27.73.
Now, we can perform a calculation for 100 machines over a year.
So, total compressed air cost for 100 machines over a year is = $27.73 × 100 ×
365 = $1,012,145.
∴ Compressed air cost (regular nozzle) for 100 machines over a year is
$1,012,145.
For Energy Savings Nozzle:
Here, the Average CFM is 56.78 & Efficiency is 96.34%.
Now, CFH (Cubic Feet per Hour) = CFM × 60 = 56.78 × 60 = 3406.80.
So, for 24 hours (1 day) = 3406.80 × 24 × 0.96 = 78492.67.
∴ Compressed air consumption per day for 1 machine is 78492.67 cubic feet.
So, total cost of compressed air for 1 machine per day is = $(78492.67 ×
0.30)/1000 ≅ $23.54.
So, total Compressed air cost for 100 machines over a year is = $23.54 × 100 ×
365 = $859,210.
∴ Compressed air cost (Energy Saving Nozzle) for 100 machines over a year is
$859,210.

Table 3. Fabric construction-wise machine efficiency & CFM data.

Machine Efficiency (%) Total CFM

CFM Reduction
Fabric Construction Regular Energy Saving Regular Energy Saving Reduction (%)
Nozzle Nozzle Nozzle Nozzle
8RSL + 9RSL × 10L70D/63 × 48 95.41 95.38 61.90 45.20 16.70 26.98
7OE × 9OE/66 × 38 95.45 95.68 63.5 54.02 9.48 14.93
20Ry × 150L40D/110 × 64 99.10 99.12 77.74 68.74 9.00 11.58
7OE × 10OE/63 × 35 95.10 95.79 66.99 60.05 6.94 10.36
7OE × 8L40D/55 × 43 95.35 95.75 64.20 55.84 8.36 13.02
Average Data 96.08 96.34 66.87 56.78 10.09 15.09

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5.1.6. Summary
Finally, we can show that our potential savings due to energy savings nozzle for
100 air-jet machines over the year is $152,935 & Individual machine savings per
year is $1529.35.

5.2. Waste Reduction—Auxiliary Selvedge Waste

5.2.1. Experimental Details
Auxiliary selvedge is a dummy or false selvedge used to hold the weft yarn dur-
ing the beat-up period. The eight warp threads that make up the auxiliary sel-
vedge are often spaced apart from the final warp ends of the main fabric. Indi-
vidual packets of warp yarns are supplied from a specific creel configuration po-
sitioned on the loom. Using a pair of scissors, the auxiliary selvedge is cut away
from the main fabric as depicted in Figure 5. All shuttle-less looms employ the
auxiliary selvedge on the left or finishing (of the weft insertion) side. The weft
yarn is held by the auxiliary selvedge during beat-up. After beat-up, some fabric
is woven, and the auxiliary selvedge, which includes both polyester ply yarn and
weft fringe, is separated from the main fabric by being cut with a pair of scissors
and accumulated in the appropriate waste box.
In this part, we used 7 warp yarns (Figure 6) as auxiliary selvedge waste in-
stead of 8 warp yarns (Figure 7) to hold the weft yarn. For this experiment, we
need to change some machine settings because the machine company provides
the instruction to use 8 warp yarns to complete the weave perfectly. So, we can
reduce waste by using 7 warp yarns and also savings an amount for this purpose.

Figure 5. Auxiliary selvedge waste.

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 Md. E. Haque et al.

Figure 6. Warp waste-7 yarn.

Figure 7. Warp waste-8.

5.2.2. Experimental Data

We used two alternative fabric constructions with cotton and polyester cloth for
this project. We mounted them in two machines and repeatedly ran them with
eight warp waste yarn and seven warp waste yarn. We finally learned what we
wanted. Machine Parameter is shown in Table 4.

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Table 4. Machine parameters & waste reduction data.

Parameters 8 Warp Waste Yarn 7 Warp Waste Yarn

Machine Brand TSUDAKOMA ZAX9100 TSUDAKOMA ZAX9100
Machine Speed (RPM) 850 850
Machine width (cm) 190 190
Reed Count (Dent/Inch) 23.5 23.5
Fabric Weave 3/1 RHT 3/1 RHT
20Ry × 150L40D/110 × 64 20Ry × 150L40D/110 × 64
Fabric Construction
7OE × 9OE/66 × 38 7OE × 9OE/66 × 38
Total number of Loom Used 2 2
Warp Beam Length (Yds) 860 860
Waste Yarn Count 32/2 32/2
Total Package Used 8 7
WBS—28 WBS—32
Machine Setting
Shed Angle—30° Shed Angle—32°
Machine Efficiency (%) 96.34 96.47
Fabric Quality No Defect Visible No Defect Visible
Fabric Inspection Point 12.14 per 100 Square yards 13.54 per 100 Square yards

5.2.3. Cost Calculation

8 Warp Waste Yarn:
Consider the reference data table which is Table 4.
Length of each warp waste yarn in auxiliary selvedge = Total beam length =
860 yds (for 1 machine/day).
No. of warp waste yarn used in auxiliary selvedge = 8
Total weight of warp waste yarn in auxiliary selvedge
8 × 860 yds 8 × 860 yds
= = ( lbs ) lbs
840 × Yarn Count ( Ne ) 840 × 32 2
= 0.52 lbs per day for 1 machine

So, total warp waste used in auxiliary selvedge for 8 yarn during the produc-
tion of 1 machine/day is 0.52 lbs.
Now, we can perform a calculation for 100 machines over a year.
∴ Total warp waste generates for 100 machines over a year is,
= 0.52 × 100 × 365 lbs
= 18,980 lbs or 8610 KG
Finally, total warp waste used in auxiliary selvedge for 8 yarn per year for 100
machine is 8610 KG.
7 Warp Waste Yarn:
Consider the reference data table which is Table 4.
Length of each warp waste yarn in auxiliary selvedge = Total beam length =

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 Md. E. Haque et al.

860 yds (for 1 machine/day).

No. of warp waste yarn used in auxiliary selvedge = 7.
Total weight of warp waste yarn in auxiliary selvedge
7 × 860 yds 7 × 860 yds
= = ( lbs ) lbs = 0.45 lbs
840 × Yarn Count ( Ne ) 840 × 32 2

So, Total warp waste used in auxiliary selvedge for 7 yarn during the produc-
tion of 1 machine/day is 0.45 lbs.
Now, we can perform a calculation for 100 machines over a year.
∴ Total warp waste generates for 100 machines over a year is
= 0.45 × 100 × 365 lbs
= 16,425 lbs or 7450 KG
Finally, total warp waste used in auxiliary selvedge for 7 yarn per Year for 100
machine is 7450 KG.

5.2.4. Summary
So, yearly waste reduction quantity due to decreasing one yarn is
= (8610 − 7450) KG
= 1160 KG
Yarn cost per KG is $3.85.
So, Total Potential Savings per Year for 100 machine is (1160 × $3.85) or $47.
We also say that warp waste reduction percentage due to decreasing one yarn is
13.47%.

6. Results
So, the summary of our work is that the potential savings per year for 100 ma-
chines for air consumption reduction is $152,935 and for auxiliary selvedge
waste reduction is $4745. From Table 5, we found the summary of this project
work.

Table 5. Result of the project work.

Result of the Project Work

Quantity/ Reduction/ Savings/100 Savings/Year

Project Project Avg. Eff Cost/Machine
Machine Machine Machine (For 100
Parameters Materials (%) (1 Day)
(1 Day) (1 Day) (1 Day) Machines)

Regular Nozzle 66.87 CFM 96.08 $27.73

Air
Consumption Energy Savings 10.09 CFM $419 $152,935
Reduction 56.78 CFM 96.34 $23.54
Nozzle

Waste 8 Warp Waste

0.52 lbs 96.34 $0.91 0.07 lbs $13 $4745
Reduction-Auxiliary (Regular)

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Md. E. Haque et al.

Selvedge Waste
7 Warp Waste
0.45 lbs 96.47 $0.78
(Experimental)

7. Recommendation
According to my above observation, I can recommend some action for the bet-
terment of cost minimization.
• At first, we need to create consciousness among the top management about
the effectiveness & profitability of cost reduction initiatives. In this report, I
have presented only two factors. We need to do this analysis for all possible
parameters of our company to minimize the process cost. When the owners’
body will realize the profitability, they will agree to take corrective action.
• Therefore, it is recommended that the minimum possible relay nozzle di-
ameter that is suitable for the filling yarn linear density used is determined
and we can save more than $0.15 M per year in air-jet weaving machine.
• Another thing is that we can save more compressed air by maintaining pre-
ventive maintenance of machines where all types of leakage will be recovered
and also, we should use air-gun during cleaning.
• We should check every air-jet machine properly during running to avoid any
type of air leakage.
• We can use the Automatic Relay Valve Drive (ARVD) function in machines
for the cotton fabric to save a lot of compressed air.
• In the second part of the work, we can strongly recommend that by decreasing
one warp waste yarn we can save a lot of amounts per year from this project.
• Waste also can be reduced by maintaining the standards of machine running
check list.

8. Conclusions
The air consumption and waste reduction on air-jet looms in a weaving mill
were reduced through an experimental study. Firstly, on looms with single-holed
nozzles, relay nozzles with 1.4 mm-diameter holes were switched out for 1.0
mm-diameter ones, resulting in a 15% decrease in air usage. Secondly, auxiliary
selvedge waste reduction of more than 13% in a year by applying a weft insertion
setting and decreasing one warp waste yarn. Thus, the weaving mill was able to
save approximately a total saving of ($152,935 + $4745) or a Total of $157,680
per year from energy costs and waste reduction with almost no expense.
In conclusion, our study demonstrated that using single-holed relay nozzles
with smaller hole diameters and making the shortest machine modifications on
air-jet looms might significantly cut energy costs and reduce waste for weaving
mills without sacrificing loom performance or efficiency.

Conflicts of Interest
The authors declare no conflicts of interest regarding the publication of this pa-

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 Md. E. Haque et al.

per.

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DOI: 10.4236/jtst.2023.91005 83 Journal of Textile Science and Technology