Ensure higher heat recovery in your textile plant with Alfa Laval’s heat exchanger system

A Fabric Dyeing and Yarn Dyeing Unit at Tirupur, India was generating almost 100,000 TPD hot effluent from processes like fabric and yarn dyeing, printing, and bleaching. The hot wash effluent has temperature streams ranging from 50 to 105 degrees Celsius. They partnered with Alfa Laval for a heat recovery system, that would help them trap and utilize this heat energy which could lead to significant savings in fuel and overall cost.

DATE 2024-05-20

There is a perception in the textile industry that heat recovery from the effluent causes pH instability and high levels of suspended solids in the effluent can lead to clogging. This can affect the heat exchanger uptime and efficiency of heat transfer, leading to an increase in the maintenance activities. Keeping these challenges in mind, a waste heat recovery system for textile effluents has been designed by Alfa Laval in partnership with their authorized partner Mangla Smart Energy Solutions. The system ensures regular cleaning of plate heat exchanger(PHE), segregation of effluent at various temperatures and continuous monitoring of heat recovery

The Heat Exchanger System helped Fabric Dyeing and Yarn Dyeing Unit at Tirupur to achieve


Maximum Uptime and Self Cleaning

Alfa Laval Wide Gap heat exchanger offers design with a flexible configuration to ensure that fibrous material don’t get stuck in plate heat exchanger (PHE). This leads to a reduction in maintenance activities.


Higher Heat Recovery

Wide Gap plate heat exchanger is capable to perform with close temperature approach. Due to this, heat recovery is very high when compared to any other technology. (For ex. if Effluent Inlet is at 80 Degree Celsius it can heat cold water upto 79 Degree Celsius when designed with 1 deg approach).


Robust System with minimal service needs

The system has been running successfully for more than a year without any service requirement. There has been a minimal need to dismantle and clean PHE in Fabric Dyeing and Yarn Dyeing Units at Tirupur as complete system has been designed keeping customer challenges in mind.


Reduction in Green House Gas Emission

Almost 1200 kgs of wood saved per day, which is equivalent to 488 tons saving in greenhouse gas/carbon dioxide emissions.

Fabric Dyeing - Case Study Details

Fabric Processing Capacity 5 TPD
Hot Effluent Discharge 100,000 LPD

Project Investment

Rs. 23,00,000
Wood Savings 1200 kgs/day
Annual Fuel Cost Savings Rs. 18,72,000
Payback - Total Investment 1.2  Years
Payback - After Subsidy 8 Months
GHG Savings – Ton of CO2 emissions Approx. 488

WideGap Heat Exchangers


Stop wasting money and energy – Invest in a sustainable future now

Energy efficiency is in our DNA. It is something we have been developing for almost a decade. In fact, Alfa Laval's heat transfer solutions save 100 GW of energy in industry every year. That is enough power to heat 20 million homes.

We have found that there is always room for reusing waste energy by changing the cleaning and maintenance program or updating the configurations. Watch the video and learn how Alfa Laval can help.

Now, we are accelerating our hunt for waste energy to improve existing industries and help you to save energy today.


Value of Reused Waste Heat

Do you cool your hot process media using a cooling system? Our online calculator can estimate how much waste heat you could hunt with one of our heat exchangers. It can even tell you how much you could save in carbon emissions, water consumption, and overall costs. Click the below button to start saving.