Spinning, weaving, processing and garments
Textile manufacturing
Textile mills run large numbers of similar machines, continuously, in energy-intensive processes. That combination makes per-machine visibility unusually valuable: small differences repeated across hundreds of machines and thousands of hours become very large numbers.
What goes wrong
Typical problems in textile
If more than two of these are familiar, there is a first project here worth doing.
- 01
Machine efficiency reported per shed rather than per machine
- 02
Stoppages and breaks recorded by rounds rather than continuously
- 03
Energy is a major cost with no attribution to machine or product
- 04
Quality issues traced back to a shift at best, never to a machine
- 05
Doffing, changeover and maintenance time is unmeasured
What we build
Solutions for textile
- 01
Per-machine production monitoring
Efficiency, output and stoppage per loom, frame or spindle set, measured continuously rather than sampled on rounds.
- 02
Energy per unit produced
Consumption attributed by machine, shift and product, revealing which assets and which product mixes are genuinely expensive.
- 03
Process parameter monitoring
Temperature, humidity, tension and speed logged continuously, connecting process conditions to quality outcomes.
- 04
Utility and plant monitoring
Compressors, humidification and chillers monitored, which in this sector is frequently the largest single recoverable loss.
- 05
Shed-level and mill-level dashboards
Live comparison across machines and sheds, with drill-down to the individual machine and shift.
Technology
What is typically involved
- Machine controller reads where available; sensor retrofit where not
- Current transformers for state and load detection
- Energy meters per machine, section or feeder
- Temperature and humidity sensing for process areas
- Large-format shed displays for live efficiency
- Long-retention time-series storage for seasonal comparison
Outcomes
What changes
Described rather than quantified — we do not publish numbers we have not measured for you.
- Machine-level efficiency comparison across the mill
- Energy cost attributable to machine and product
- Stoppage patterns visible per machine rather than per shed
- Utility losses, especially compressed air, made visible
- Maintenance prioritised by measured performance
Capabilities
Most relevant here
- Machine MonitoringReal-time machine, production and downtime monitoring with OEE.
- Industrial IoTGet data off your machines — existing PLCs, new sensors, or both.
- Predictive MaintenanceCondition monitoring and early warning on critical assets.
- Industrial DashboardsReal-time plant dashboards for the floor, the office and the phone.
- Edge Computing & GatewaysIndustrial gateways, protocol conversion and processing at the plant.
Questions
Textile — common questions
We have three hundred looms. Is monitoring all of them practical?
Yes, and the per-machine cost falls considerably at that scale because the design work is done once and replicated. We would normally prove it on one shed first, then roll out — both to validate the approach and because the first shed always teaches you something about the rollout.
Our machines are quite old. Does that rule this out?
No. Age is rarely the obstacle; the question is whether the machine exposes anything electrically. Almost all do — a motor to sense current on, a moving element to count, a drive to read. Machines from the 1980s are monitored routinely.
Tell us about your textile plant
What runs on your floor, and what you cannot currently answer. We will tell you what is readable today and what a first phase would involve.