Rubberized coir mattresses is formed from coir and latex rubber is an industrial process. Heat delivery of 0.5 to 1 million kilo cal boilers ( either steam or thermic fluid, operated by fossil fuels ) are needed for process heat in the production line . The considered factory uses 0.5 million kilocal capacity thermic fluid burner which uses around 900 – 1200 kg fire wood per hour to heat thermic fluid for transferring heat to different thermal applications mainly at 4 stages namely:
1. Drying out moisture in coir coil by placing them in an enclosure heated to 70 °C.
2.Sheet forming machine in which air is heated to 70 – 80 °C
3.Vulcanising machine where air is heated to 120 °C.
4. Calendar pressing sheet by contact heat at 150 °C.
By using solar pre heated air at 60°C to 95° C (depending upon the solar radiation), the firewood consumption for the sheet making dryer could be reduced. The solar heating unit saves fossil fuel around 50 to 60%. – fire wood savings will lead to protecting our forest and also diesel used in the transport of firewood. As the mattress factory has many emission, usage of solar heating will lead to cleaner environment.
A 284 m2 area solar air heating system was installed at Eastern Mattresses Pvt.Ltd, Iduki District Kerala integrating on the south facing factory roof The hot air obtained is drawn by an electrical blower. The hot air is transmitted by insulated metal pipes to the fresh air inlet point of the dryer to preheat the air required for the dryer. Firewood savings of around 54 % was recorded.
Eastern Mattresses Pvt.Ltd, Idukki District, Kerala India.