Just recently we have established small spinning mill of 2200 spindles in a remote village in Bhavnagar District. It is just same machinery as conventional spinning mill i.e. Blow room, card, draw frame, speed frame, 5 ring frames of 440 spindles and cone winding machine. We have connected cotton ginning with it to produce lint cotton. I am sure it will be highly profitable. We have purchased old running machinery from Ahmadabad and shifting it to a village. I have decided not to earn a single rupee from this activity. During this process, I am pondering over further decentralization of spinning machinery. I am not at all expert in this field but I have deep rooted faith in my heart that everything must be decentralized upto village scale and home scale. So I am narrating my ideas and you can give me your opinion whether it is foolish or it has some sense.
1) Blow room has 6 to 7 motors. I do not know what is process in it, but I felt that if we reduce the effective width of the blow room machines to 25%, then motor HP should also be 25%. So if motor is of 1 HP or less, then PV panel can work to generate that much power easily. Total load of blow room is say 20 HP and then it becomes 5 HP with 5 to 6 different motors of 1 HP or less, then all these motors can be operated by solar panels. Fast production and high production is not the criteria in village economy. So if production capacity is reduced by 20 times i.e 5% only then it will be best suited to village size blow room. Conveying and elevating can be totally removed and human labour can be replaced. Effective width should not be more than 6 to 8 inch. Please do not bring question of viability for such a small unit. I have proved in 85 countries practically that my tiny oil mills are far more viable than giant oil complexes. So I am sure that blow rooms, once produced in hundreds of pieces will be far cheaper. I am master of making the machines very cheap. You kindly advise me technical feasibility.
2) Carding machine also can be reduced in width say 25% or 6 to 8 inch width and diameter can also be reduced 25% or 50% so that 3 HP motor becomes 0.5 HP motor in tiny card. Please give me your views whether this is possible or not.
3) I have seen draw frame with 2 parallel lines in which 8 ropes are going together to make one rope but 8 times longer. Some how this machine should also be operated by half to one HP motor to process 4 ropes only and we have to repeat this process twice or thrice with the same machine of one HP or less.
4) I have seen the speed frames of 96 and 132 spindles which can be reduced to 16 spindles simply by cutting the length so that it may be driven by 1 HP motor. I understand that head, gears etc will cost more but it can be simplified with simpler and cheaper gears as we see in Amber Charkha.
5) Ring frame in conventional form of 440 or more spindles is not required at all. One expert textile engineer with 35 years of experience in big textile mills told me that spinning quality of Amber Charkha will be same as big ring frames in textile mills. Amber Charkha consumes less power per kg of yarn compared to big textile spinning ring frames.
6) Cone winding also can be split up from 120 to only 10 to 12 cones and motor size will also be reduced to 200 Watt instead of 3 HP.
In this way I have thought out a concept of entire spinning mill run by many motors with total load of 10 HP but all motors will be smaller than 1 HP. All motors will be DC motors and there will be totally solar power. So energy bill will be zero. If this is technically feasible, then I have a full courage to make it economically viable. I have no knowledge of textile technology at all. But still I feel that there must be some way to utilize modern textile technology into villages with solar power. If this solar powered spinning mill becomes equivalent to 100 spindles production of big textile mill, then it will become viable in villages and it will be owned by farmers and mostly yarn will be produced in farms itself not bringing the cotton in village.
I have observed that when technology is disseminated upto grass root level, then most sophisticated machines can also be produced at throw away price by common people. This has become reality in Rajkot in case of Lister and Peter diesel engines which are produced in abundance even by illiterate people maintaining very high accuracy. So I am confident that decentralization of spinning technology must be possible.
If you know some persons in textile technology who are committed for decentralization, kindly put them into my contact. I will highly appreciate your valuable opinion in this matter, no matter it may be against my thinking.
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