Eco Heater for Yarn Texturing
The TSP Eco Heater is a directly electrically heated primary heater designed to reduce heating energy consumption while maintaining yarn quality. At the process conditions shown below, the comparison gives approximately 56.7% lower total heating power demand than the open heater.
Heating Principle
The Eco Heater uses a closed yarn path and full contact electric heating. It does not use Dow Therm heat transfer fluid, eliminating fluid handling, leakage, degassing and fluid related cold tops from the heater system.
The closed heater concept was first introduced on Rieter ICBT texturing machines and has since been widely adopted by Indian and Chinese manufacturers.
Key Benefits
Lower Energy Demand
Reduced heater power consumption lowers operating costs and heat released into the production room.
Consistent Yarn Quality
Uniform heat distribution and a closed yarn path support consistent yarn properties and dyeability.
Rapid Start up
Direct electric heating supports fast warm up, shutdown and restart without managing a vapour phase fluid system.
Maintenance on Site
Exchangeable yarn tubes and standard components allow routine cleaning and servicing at the customer’s facility.
Reduced Room Heat Load
Lower heat loss can reduce the cooling demand placed on the production room’s air conditioning system.
System Specifications
Heater Type
Direct electric, full contact primary heater with a closed yarn path.
Positions per Heater
3 twin units, providing 6 yarn positions.
Heater Length
1.00 to 2.50 m.
Supply Voltage
Three phase, 380 V.
Temperature Sensors
3 × PT100.
Temperature Control
Modern PID control system with independent and global control options and an HMI touchscreen display.
Temperature Range
Ambient to 280°C
Fume Removal
Exhaust provision at both the heater inlet and outlet.
Threading
Compressed air suction gun.
Complete Heating System
Eco Heater Unit
The heating unit for the selected machine configuration.
Threading Assembly
The heater threading assembly for integration with the existing yarn path.
Temperature Control
A heater temperature control system with HMI display.
Energy Comparison
The comparison uses the same yarn, speed, heater length and temperature conditions for both systems. Power figures are stated per yarn position.
Eco Heater
74.29 WTotal Heating Power per Yarn Position
£13,659.26Indicative Annual Heating Cost for 120 Positions
Open Heater
171.65 WTotal Heating Power per Yarn Position
£31,560.25Indicative Annual Heating Cost for 120 Positions
Annual cost basis: £0.19/kWh, 48 weeks per year and approximately 168 operating hours per week. See the cost breakdown below.
Shared Operating Conditions
- Machine Process Speed (m/min)
- 250
- Yarn Linear Density (dtex)
- 110
- Primary Heater Length (m)
- 2.00
- Ambient Temperature (°C)
- 26
- Primary Heater Setpoint (°C)
- 230
- Yarn Temperature at Heater Exit (°C)
- 229.1
- Yarn Mass Flow (kg/s)
- 0.0000458
- Specific Heat of Nylon 6.6 (J/(kg·K))
- 1700
Power Comparison per Yarn Position
| Parameter | Eco Heater | Open Heater |
|---|---|---|
| Power Required to Heat the Yarn (W) | 15.82 | 15.82 |
| Heater Heating Power (W) | 58.47 | 155.83 |
| Total Heating Power (W) | 74.29 | 171.65 |
The total power reduction is 97.36 W per position, equivalent to approximately 56.7% under these comparison conditions.
The stated installed element rating of 3 × 200 W is different from operating power demand; it is not a continuous consumption figure.
Indicative Heating Costs for 120 Positions
Electricity tariff: £0.19/kWh. Annual production basis: 48 weeks. Weekly estimates correspond approximately to continuous operation for 168 hours.
| Cost Measure | Eco Heater | Open Heater |
|---|---|---|
| Energy Cost per Kilogram | £0.09 | £0.20 |
| Energy Cost per 4.00 kg Package | £0.34 | £0.79 |
| Heater Energy Cost per Week | £284.57 | £657.51 |
| Heating Cost per Year | £13,659.26 | £31,560.25 |
Indicative annual saving: approximately £17,901 for 120 positions. Costs are rounded estimates; actual savings depend on operating hours, electricity tariff, process settings and production output.
Heater Operation and Temperature Control
The open heater described here is the existing Dow Therm vapour phase system used for this comparison. Features and service arrangements may differ on other open heater installations. Both compared heaters have a 2.00 m length; the Eco Heater range is 1.00–2.50 m.
Heating Method
TSP Eco Heater: Direct electric contact heating without a heat transfer fluid.
Open heater: Dow Therm liquid operating as a vapour phase heat transfer system.
Energy Demand
TSP Eco Heater: 74.29 W per position at the stated comparison conditions.
Open heater: 171.65 W per position at the same conditions.
Start up and Shutdown
TSP Eco Heater: Rapid start up; the heater can be switched off when production does not require heating.
Open heater: Slower warm up is required to manage the heat transfer fluid and avoid degradation.
Heat Load
TSP Eco Heater: Lower element ratings and reduced heat loss can lower room cooling demand.
Open heater: Higher heat loss increases the heat load in the production room.
Control System
TSP Eco Heater: Modern modular controls, standard sensors and independent or global control options.
Open heater: The compared installation uses a legacy control system more than 20 years old, with obsolete PCB components.
Temperature Range
TSP Eco Heater: Ambient to 280°C
Open heater: 140°C to 260°C in the compared installation.
Compared Heater Arrangement
TSP Eco Heater: 3 twin units, 6 positions and a 2.00 m heater length.
Open heater: 3 twin units, 6 positions and a 2.00 m heater length.
Fume Removal
TSP Eco Heater: Exhaust at the heater inlet and outlet.
Open heater: Exhaust at the heater inlet and outlet.
Maintenance and Yarn Handling
Routine Cleaning
TSP Eco Heater: Quick yarn tube exchange allows cleaning in house with a brass brush.
Open heater: Manual cleaning with metal brushes or scrapers requires reduced power or shutdown.
Fluid Management
TSP Eco Heater: No Dow Therm fluid, degassing or fluid related cold tops.
Open heater: Fluid leakage and gas build up can require attention; cold tops can affect yarn quality.
Repairs and Servicing
TSP Eco Heater: Designed for maintenance on site using serviceable, industry standard components and sensors.
Open heater: The compared system relies on one overseas supplier and return to Italy for repairs, increasing cost and downtime.
Threading Method
TSP Eco Heater: Compressed air suction gun.
Open heater: Manual push/pull rod with sledge and tipper arm.
Restarting the Machine
TSP Eco Heater: Yarn can remain threaded to the cooling track, supporting a faster restart.
Open heater: Yarn can catch or misthread if heater and threading components are misaligned.
Threading Maintenance
TSP Eco Heater: Avoids the rod, sledge and tipper arm maintenance associated with the compared threading system.
Open heater: Threading parts require replacement and periodic realignment.
Yarn Quality
TSP Eco Heater: The closed yarn path reduces misthreading risk and supports uniform heating and dyeability.
Open heater: Catching or misalignment can cause variation in yarn quality.
Materials and Disposal
TSP Eco Heater: Recyclable construction with no heat transfer fluid to handle.
Open heater: Servicing and disposal require handling of the heat transfer fluid.
Customer Trial
A customer trial provides the opportunity to verify yarn quality, threading performance, temperature control and energy use under the intended production conditions.
Controlled Heating
Direct electric heating with a closed yarn path and full yarn contact.
Energy Efficiency
Assess energy use against the existing heater under comparable running conditions.
Simplified Maintenance
Operation without heat transfer fluid removes fluid handling and leakage tasks.