Toray cuts its cloth according to Fuel+ from Maxsys
24 October 2006, News release from Maxsys Ltd
Toray Textiles Europe Ltd, a leader in advanced synthetic fabric manufacture, has achieved impressive energy savings of over 5 per cent per annum through the installation of the Fuel+ energy saving solution from Maxsys at its state-of-the-art textile production facility in Mansfield.
While the UK textile industry may have contracted, Toray is a progressive UK manufacturer that has invested in the latest technology and deployed innovative process engineering. Today Toray employs 350 employees and generates annual turnover in the region of £30 million.
Having weathered the storm of low cost overseas competition, soaring energy costs are the last thing required by any UK textile producer. With this in mind, Toray Textiles decided to investigate the Fuel+ from Maxsys as part of its strategic commitment to cut unit energy consumption by 2 per cent per annum. Fuel+ operates by applying a precisely calibrated magnetic field to the fuel supplied to the burners. This pre-treatment process enhances combustion, thereby producing a cleaner burn and reduced carbon emissions. Fuel+ units are designed for installation into vertical or horizontal pipes, there are no moving parts and no electrical supply is required.
"Energy efficiency is an important issue for us at Toray and plays an integral part in our environmental policy," said Mike Fisher, General Manager - Engineering. Toray Textiles, which is ISO14001:2004 certified, has an environmental policy that includes a commitment to manage responsibly its impact on the environment. One of its environmental principles states: 'to make efficient use of energy, optimise the use of energy where practicable, and minimise greenhouse gas emissions'.
"The impact of energy prices means we are always looking to be proactive in energy management," said Mr Fisher. "We have year-on-year objectives and targets, one of which relates to our boiler efficiency and to reduce the amount of gas consumed. We knew that Fuel+ would provide benefits in this area."
The Mansfield site has three 35,000lb, gas fired, steam-raising boilers which act as duty, standby (for peak demand) and dry storage, and are rotated every 12 months. Fuel+ was installed on one of the boilers in December 2004. ABB were selected as the company to carry out an independent evaluation of the effectiveness of the Fuel+(TM) system.
"The installation was carried out by Maxsys Ltd during our Christmas shutdown. In mid March 2005 we received a report from ABB showing a 5 per cent reduction in gas consumption per tonne of steam produced, as Maxsys had guaranteed," said Mr Fisher. "We found that Fuel+ offered maximum return when demand was high, which is something that suits our operations at Mansfield. Overall it has provided us with a significant improvement in energy use."
"Another advantage of Fuel+ is that it helps reduce the amount of carbon dioxide being emitted," confirmed Mr Fisher, "during a 20 day period 12,400m3 less gas was consumed than would have been expected if the Fuel+(TM) had not been installed. I was so pleased with the results that we asked Maxsys to install a Fuel+(TM) system to another boiler."
Maxsys provides cost effective energy saving equipment across a wide range of industries, including food and drink, chemicals, paper, steel, minerals, textiles, cement, glass, printing, rubber, manufacturing and bricks, as well as process and space heating for the public and private sectors. Maxsys offer guaranteed savings of at least 5 per cent or any capital outlay is returned. Other benefits include a reduction in emissions that provides assistance in achieving the Climate Change Levy discount, as well as reduced maintenance and downtime.
Toray Textiles Europe Ltd is a wholly owned subsidiary of Toray Industries Inc, the largest manufacturer of woven polyester and nylon fabrics in Europe. The company's purpose-built manufacturing plant at Mansfield produces fabrics for use in sportswear, furnishings, fashion, lingerie, corporate clothing and school wear, as well as technical fabrics for applications such as clean room, surgical and medical.
In the latter sector, Toray has recently made a breakthrough with its 'See it SAFE(TM)' product range of fabrics containing silver yarn, which are now available to health care professionals across the UK. These Fabrics have been proven to provide significant improvements in several areas of patient care including their ability to completely kill the MRSA and vMRSA bacteria on contact. Toray is the only woven textile manufacturer given the go-ahead by the NHS Rapid Review Panel for the 'See it SAFE(TM)' fabrics for bedding, sheeting, surgical gowns and drapes.
For further information please email Maxsys Ltd