Final report basic CP IVAM

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Bangladesh Water PaCT: Partnership for Cleaner Textile Final Report on 50 Basic Cleaner Production Assessments (Step 2) in the PaCT Prepared for IFC Bangladesh IVAM UvA BV, Amsterdam, The Netherlands SEBA Limited, Banani, Dhaka Amsterdam January 26, 2016 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 2 About PaCT PaCT is a partnership between textile wet processing factories in Bangladesh, international apparel buyers, wet processing technology suppliers, the Embassy of the Kingdom of the Netherlands (Dhaka), the International Finance Corporation (IFC), and the NGO Solidaridad. The PaCT partners share a commitment to bring about systemic, positive environmental change for the Bangladesh textile wet processing sector, its workers, and surrounding communities, and to contribute to the sectors long-term competitiveness. To this end, the PaCT partners are collaborating to develop harmonized resource-efficiency procurement requirements, to build factory capacity, technical knowledge, and access to finance for Cleaner Production Estimated investments, and to create a platform for community and national dialogue on sustainable use of water in the textile sector. IFC has commissioned IVAM UvA BV (the Netherlands) to support the local service provider SEBA Ltd based in Dhaka, Bangladesh in the execution of 50 basic CP assessments. IVAM UvA BV operates in this project in consortium with Environmental Management Centre LLP (India) and ISB (Sri Lanka). Disclaimer and Limitations IFC, a member of the World Bank Group, creates opportunity for people to escape poverty and improve their lives. We foster sustainable economic growth in developing countries by supporting private sector development, mobilizing private capital, and providing advisory and risk mitigation services to businesses and governments. This report was commissioned by IFC as part of implementing the Bangladesh Water PaCT: Partnership for Cleaner Textile. The conclusions and judgments contained in this report should not be attributed to, and do not necessarily represent the views of, IFC or its Board of Directors or the World Bank or its Executive Directors, or the countries they represent. IFC and the World Bank do not guarantee the accuracy of the data in this publication and accept no responsibility for any consequences of their use. This report has been based on the available documents and verbal communication with factory staff and management. It is important to notice that although some compliance issues related to WASH and OHS are discussed, this report has not been prepared for compliance purposes. The content is based on voluntary information provided by the factory management and test data generated by the local service provider and factory staff. The information is time dependent, and the relevance of data, conditions of site and observations may change. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 3 Table of Content Executive summary 1 Introduction .................................................................................................................................. 9 1.1 Overview of Textile Sector in Bangladesh ........................................................................................... 9 1.2 Response to Textile Issues in Bangladesh ........................................................................................... 9 1.3 Benefits of Cleaner Production in Textile ......................................................................................... 10 1.4 Deliverables ....................................................................................................................................... 10 1.5 Project Team ..................................................................................................................................... 10 2 PaCT Cleaner Production Assessment Methodology ................................................................ 14 2.1 Overview of Textile Processing ......................................................................................................... 14 2.2 Cleaner Production Assessment Methodology ................................................................................. 16 2.3 Pre-Assessment and Walkthrough Assessment ................................................................................ 19 2.4 Collection of Data & Analysis ............................................................................................................ 20 2.5 General Issues Identified................................................................................................................... 21 2.6 Debriefing of Cleaner Production Report ......................................................................................... 22 2.7 Preparation and Submission of Report ............................................................................................. 22 2.8 Preparation of Action Plan ................................................................................................................ 22 2.9 Consultants Visit Details................................................................................................................... 22 2.10 Capacity Building of Local Consultants ........................................................................................... 23 3 Cleaner Production Implementation .......................................................................................... 24 3.1 General Overview ............................................................................................................................. 24 3.2 Individual Factory Implementation ................................................................................................... 26 3.3 Financial Impacts of the Pilot Project ............................................................................................... 76 3.4 Resource Saving and Environmental Benefits .................................................................................. 76 4 Cleaner Production Calculation Methodology........................................................................... 78 5 User Group Methodology & Findings ....................................................................................... 86 5.1 USER GROUP METHODOLOGY & FINDINGS: ..................................................................................... 86 5.2 User Group Meeting as organized by SEBA ...................................................................................... 91 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 4 6 Conclusion ............................................................................................................................... 101 6.1 Constraints ...................................................................................................................................... 101 6.2 Achievements & Success ................................................................................................................. 102 6.3 Lessons learnt ................................................................................................................................. 102 Annexes (upon request) 1. Pre-assessment questionnaire 2. Checklist (Utility, process, ETP, WASH, OHS&EMS) 3. Action Plan Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 5 Executive Summary In 2014 and 2015 IVAM UvA BV and SEBA Ltd assessed 50 wet textile processing in Bangladesh based on the CP methodology. This report describes the results of those 50 basic CP assessments including a 6 month monitoring phase in which the implementation of the identified options were monitored. In this type of assessment the obvious options are identified and their benefits calculated. Obvious options concern the (almost) visually present signs of waste and leakages whose volumes and costs are underestimated. Obvious options are mostly in the order of improved control of parameters, improved maintenance, improved handling of resources, recycling and reusing. Obvious options hardly require thorough analysis and lengthy measuring periods to prove their economic and environmental feasibility. Implementation is overall speaking also relatively easy. Most commonly observed options are: Recommendation Option and example investment USD Economic benefits, USD/year Payback time, year Process modification At Noman Terry Towels Ltd an analysis of acrylic cotton yarn dyeing, showed that one wash step can be dropped. 0 50,065 Instant Water trigger nozzle Noman Terry Towel Ltd installed 10 water trigger nozzles. 58 733 0.1 Cooling water recovery Envoy Textiles Ltd recovered cooling water from gas singeing machines 7,802 2,488 3 Waste heat recovery boiler (WHRB) Modele De Capital Industries Ltd installed a WHRB of 2 ton/h 206,245 52,399 4 Condensate recovery Ring shine Textiles Ltd recovers the condensate from Hank dyeing & spray Dyeing section 154 60,786 Instant Insulation of hot surfaces Noman Terry Towel Ltd insulated 2 feed tanks, 12 valves and 48 sq. feet steam lines. 2,167 1,436 1.5 Air trigger nozzle Esquire Knit Composite Limited 60 no's installed 6 air trigger nozzles. 140 15,408 Instant Variable Frequency Drives Mondol Knit Composite installed 6 VFDs. 11,000 3,866 2.8 Installing energy efficient LED light Paramount Textile installed 3200 LED light (22 watt) 24,410 6,936 3.5 Improving metering system Textown Ltd installed 6 water flow meters 13,271 0 0 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 6 Financial implications In the 50 CP company assessments 545 options were recommended which may incur an estimated total investment of 5,626,789 USD with which an total potential benefit of 3,605,020 USD can be obtained. The estimated payback is on average nineteen months. After a six month monitoring period it was concluded that 185 options (34% of the suggested/agreed recommendations) have been implemented with a total investment value of 1,592,909 USD and generating economic benefits of 768,020 USD per year. Simple payback of the investment is 2 years. Resource saving and Environmental benefits Within the monitoring period 185 options out of 545 identified options have been implemented by the 50 companies which have generated the following resource savings and environmental benefits. Water consumption The 50 companies managed to reduce their water consumption with 1.97 million m3 which is over 5% of the original annual consumption of 38 million m3. Of the 1.97 million m3 reduction 1.59 million m3 was obtained in the wet textile processing units. Natural gas The 50 companies managed to reduce their natural gas (NG) consumption with 10.3 million m3 which is approximately 3% of the original annual consumption 404 million m3. The corresponding financial value of the NG saving is 645,109 USD Electricity The 50 companies managed to reduce their electricity consumption with 10,389 MWh which is approximately 2% of the original annual consumption 288,284 MWh. Saving resource is equivalent to 1.64 million USD per year. Steam The 50 companies managed to reduce their steam consumption with 34,389 ton which is approximately 1.3% of the original annual consumption 2,617,187 ton. Greenhouse gases The 50 companies managed to reduce their greenhouse gases generation with 20,946 ton which is approximately 3% of the original annual generation of 794,078 ton. Wastewater The 50 companies managed to reduced their wastewater generation with 1.59 million m3 which is approximately 5% of the original annual generation of 28.9 million m3. Implementation of policies and procedures Most companies have implemented all proposed policies and procedures regarding chemical inventory, occupational health and safety (OHS), water availability, safety and hygiene (WASH) and environmental management systems (EMS). In the 50 companies the policies recommended and implemented are as follows. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 7 Topic recommended Implemented during the 6 months monitoring period Implementation rate OHS 227 195 86% Chemical inventory 49 47 96% EMS 141 111 79% WASH 149 133 89% Qualitative changes Apart from the implementation of the options which yielded quantitative benefits also changes have been made which improved safety, working atmosphere etc. Most factories made positive changes in following areas: Improving floor markings and housekeeping conditions. Redesigning chemical storage for safe storage of chemicals as well as to ensure good handling and spillage control. Ensuring proper labeling and signage at work places. Providing rubber mats in front of electrical panels to ensure people safety. Developing new standard operating procedures. Awareness raising and motivating workers to practice energy and water saving continuously. Providing training to ensure a shift of mindset towards CP practices. Constraints Prior to the actual assessment a low awareness of management was the main constraint. This is caused by the priority setting which is mostly dominated by production issues and by underestimating the costs for water, energy and material losses. The initial assessment, or the questionnaire, and one-on-one talks by the local coordinator did raise the awareness to the level that when starting the assessment the relevant staff and management was present and aware and a limited amount of data was available. Also most factories had at that stage already established a basic CP team. Another result of the intensive preparation was that the local and international team were allowed to go everywhere in the factory premises and allowed to talk to everybody. Generally the atmosphere in which the first visits took place was considered to be pleasant and open. Availability of baseline data In most of the cases, availability of baseline data was the challenge. The main reason was the lacking of proper metering system and even metering systems are available, in some cases, data logging wasnt consistent. On the other hand, there were some exceptional factories where data logging were present in most areas and even some sort of analysis was seen which is encouraging. Due to unavailability of baseline data, the working team had to spend time for collection of data (where meters were available) or had to adapt indirect calculation method based on physical checking at site. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 8 During the implementation phase the situation regarding the metering did improve somewhat however still many meters are necessary to improve the resource management in the 50 factories. Meters installed (based on 50 CP assessments) Before (During Assessment) After (During Follow-up visit) % of flow meter increased Water flow meter 244 293 20 Electricity meters 114 123 8 NG meters 89 89 0 Steam flow meters 12 19 58 Achievements & Success Due to the continuous attention of the local service provider and detailed support by the local team in each and every CP assessment the 50 CP assessment can be considered an achievement. Drop out of companies were minimal and certainly much lower than what can be commonly expected in voluntary CP programs (>10%). The strenuous selection procedure as executed by IFC is largely responsible for this success. Off course all involved organizations played their respective part in the project and are responsible for its success. Also after the assessment period the majority of companies show a good commitment to the CP approach and have started to implement a significant number of options. Apart from a few exceptions it can be in general agreed that the project has been successful in initiating improvement programs in a significant number of companies. Especially when considering the diversity in size, process, product and management maturity and age. The teams have overcome most barriers when regarding data collecting, option generation and implementation. Lessons learnt The initial access is always a challenge to convince the factory team and ensure support and participation from them. The best approach is to earn the mandate from top management and maintain a good peer relationship with factory CP team. Proper interpretation of project highlights and expectations plays also a good role in maintaining a good relationship. Comparing available data with realistic benchmark figures play an important role to convince management and these available data need to be verified in order to make sure that the represent the actual situation. The user Group meeting plays a good and effective role on enhancing the understanding of CP among the audiences. The cross factory team communication can unfold lots of new thoughts and spread the real benefits of implementation among the operation people. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 9 1 Introduction 1.1 Overview of Textile Sector in Bangladesh The textile industry in Bangladesh is responsible for 80% of the export earnings. It is a 18 billion USD industry and contributes approximately 30% to the Bangladesh industrial sector GDP. The sector employs 3.6 million people of whom 85% are women. 1.1.1 Environmental Issues of Textile Sector There are approximately 1,700 washing dyeing and finishing units whose effluents impact the lives of 12+ million Dhaka residents. The groundwater depletion by industry causes the water tables to decline with 1 to 2 meters/year which leads seasonal water shortages. 1.1.2 Energy Issues of Textile Sector Most wet textile processing industries convert the natural gas to electricity and steam using generators and boilers. The electricity is mainly used for generating compressed air and operating pumps, engines, ventilators, lighting, etc. whereas the steam is used for heating the processes baths and for drying operations. Due to the instability of the natural gas grid many factories have diesel generators on standby. 1.1.3 Wastewater disposal issue After the tannery industry section the textile sector is the biggest polluter which significantly impacts the surface water and groundwater quality. The sector consumes 1,500 billion liters of groundwater per year for the production of 5 million tons of fabric (300 liter per kg fabric on average) 1.1.4 Occupational Health and Safety Since the Rana Plaza and Tazreen disasters the attention for the safety in the textile has ramped up and many factories have joined initiatives like ACCORD and Alliance to improve their OHS situation. 1.2 Response to Textile Issues in Bangladesh Cleaner production is a way to improve the sustainability of the textile industry by improving the management and reducing resource consumption. Other initiatives to improve sustainability are based on occupational health and safety (OHS or OHSAS18000), environmental management systems (EMS or ISO14000), water availability safety and hygiene (WASH). The Detox campaign by Greenpeace and the ZDHC (zero discharge hazardous chemicals) initiative showed that the textile industry uses chemicals which are toxic to humans and/or endangering the environment. Brands are now engaging textile industry to avoid this kind of chemicals. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 10 1.3 Benefits of Cleaner Production in Textile Cleaner Production is the approach that by implementing process integrated measures resources can be saved and environmental impacts reduced. When resource consumption indicators are high this illustrates poor management of resources and the first step of CP is to analyse the causes of these inefficiencies. In principle the environmental impacts and causes can be due to poor resource management, operating procedures, equipment, waste characteristics, technology and the product itself. When a textile industry hasnt considered resource management, improved technology and equipment operations, metering of resource consumption, monitoring and implementation of CP recommendations in utility, process and waste managements may reduce water consumption on average with 40% and energy with 20%. 1.4 Deliverables The deliverables of the IVAM terms of reference are: CP capacity building of the local service providers 50 CP assessment reports 50 company debriefings Support the development of 50 action plans Support the development of 50 monitoring reports Support the development of case studies A final report 1.5 Project Team IVAM team Name Role Assignment in the project Jaap van der Meer IVAM Project manager and senior Cleaner Production expert. Background in Chemical engineering Project management CP training Company visits and debriefing Support publications Rahul Datar EMC OHS/WASH expert OHS/WASH in textile industry Helpdesk regarding OHS/WASH Shantanu. Roy EMC Vice project manager and senior advisor Cleaner Production. Background in chemical engineering (co) project management CP training Company visits and debriefing Support publications Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 11 Mahesh Sharma EMC Textile engineer Developing textile engineering training module Training textile engineering Company visits and debriefing Helpdesk regarding textile engineering Dinesh Kamath EMC Electrical engineer/ energy auditor Developing electrical engineering training module Training electrical engineering in textile industry Factory visits (training group (6) Helpdesk regarding electrical engineering Loshan Palayangoda ISB Mechanical engineer Developing mechanical engineering training module Training mechanical engineering in textile industry Factory visits and debriefing Helpdesk regarding mechanical engineering Chanaka Mahawatta ISB Chemical engineer Developing chemical engineering training module Training chemical engineering in textile industry Factory visits (training group (6) Helpdesk regarding chemical engineering SEBA Ltd team: Name Role Assignment in the project Hasan Iqbal Team Leader Team building Communication with stakeholders Planning Logistic support Report review Kamrul Ahsan Dewanjee Deputy Team Leader Team management and delegation of authorities Data analysis Communication with IVAM technical team Assessment report drafting Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 12 Supporting monitoring activities Md. Habibul Islam Senior Consultant (textile) Leading the local wet process team Extending support in trial and option verification Communication with factory CP team A.K.M Alauddin Team Leader (monitoring) Communications with factory for monitoring planning Ensure monitoring visits and having validation documents Ensure updating of monitoring documents Abdullah Ash Shakir Project Engineer (electrical) Assist the wet process team Ensure all calculations of wet process options Co-ordinate with team leader for verifications Maintain all related documents Abu Bin Jubaer Project Engineer (textile) Assist the wet process team Ensure all calculations of wet process options Co-ordinate with team leader for verifications Maintain all related documents Aurangazeb Project Engineer (mechanical) Assist the CP assessment team Ensure all calculations of boiler/steam related options Co-ordinate with team leader for verifications Maintain all related documents Faisal Rahman Project Engineer (electrical) Assist the CP assessment team Ensure all calculations of water/electrical related options Co-ordinate with team leader for verifications Maintain all related documents Mahfujul Alim Project Engineer (electrical) Assist the CP assessment team Ensure all calculations of water/electrical related Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 13 options Co-ordinate with team leader for verifications Maintain all related documents Sadnam Saniat Hasan Risat Project Engineer (electrical) Assist the CP assessment team Ensure all calculations of electrical related options Co-ordinate with team leader for verifications Maintain all related documents Support in draft report writing Sharmin Akter Project Engineer (electrical) Ensure support for OHS/EMS/WASH/Chemical management assessment Co-ordinate with team leader for verifications Maintain all related documents Maintain overall data banks 1.6 Objective of Final Report The objective of the final report is to describe the results obtained with respect to the financial implications in terms of investment and economic benefits, resources saved and environmental impacts reduced. The major topics to report on are: - Summary of major conclusions and recommendations - Assumptions and calculation methodology used to estimate savings - Number of recommendations implemented - Total amount invested by the factories - Cumulate savings by the factories due to savings from water, energy and GHG emissions avoided - Estimated water savings in liters and associated cost savings - Estimated energy savings and associated savings - Estimated GHG emissions avoided - Estimated number of policies, procedures, etc. that were eliminated/improved at each of the factories - Estimated percentage reduction in total operational cost at each of the participating factories Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 14 2 PaCT Cleaner Production Assessment Methodology 2.1 Overview of Textile Processing The textile industry is among the largest industries of the world with regard to production and labor. It exhibits a typical variation in scale: from large scale mechanized to small scale traditional units. Broadly this industry is classified into the cotton, woolen en synthetic fibers industries. Wet textile processing is performed in a multistage operations which contain the following steps: 2.1.1 Sizing In sizing the warp threads are coated with size (either starch or synthetic) to facilitate weaving by giving the threads tensile strength and smoothness. The component is then dread on the threads and remains a part of the cloth until it is removed in the subsequent processes. Generally the sizing step is not considered to be part of the wet textile processing but part of spinning and weaving. 2.1.2 Desizing The purpose of desizing is to remove sizing ingredients , mainly starches, gums, PVA etc. The gums and PVA are removed by a simple hot wash but starch has to be degraded first into small molecules. These molecules being soluble in water are then removed through a hot wash . The desizing project is important because the presence of starch on the fabric hampers the penetration op other chemicals in the subsequent processes. 2.1.3 Scouring Cotton being a natural fiber contains about 2 to 3% of different impurities such as waxes, fatty acids, proteins, pectin, and mineral matter. Scouring removes natural impurities other than coloring matter, particular from cotton fibers, This process is performed under highly alkaline conditions at temperatures conventionally above 1000C. 2.1.4 Bleaching Bleaching is basically the process to destroy the natural coloring matters present in the cotton. Three typical processes are available for bleaching: sodium chlorite, sodium hypochlorite and hydrogen peroxide bleaching. 2.1.5 Mercerizing The mercerization process is basically an alkali (NaOH) treatment given to cotton yarn or fabric so that the cotton fibers swell and attain a round-like structure from the original convoluted form. The axial ration of the cross section is reduced due to rounding. When performed under tension for 40 to 50 seconds with caustic soda this process improves luster, strength and dye uptake. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 15 2.1.6 Dyeing Dyeing is a process or combination of processes which is performed to give a reasonable permanent coloration to the textile fabric. The dyeing should offer a reasonable fastness to: household washing and laundering, light, rubbing, oxidation and sublimation, perspiration. 2.1.6.1 Dyestuffs All classes of dyestuffs are chemically different and applicable for different fibers with different application methods. The most common are: Vat dyes: insoluble dyes are made soluble using a reducing agent (sodium hydrosulphate) and oxidized and made insoluble again when attached to the cellulosic fibers Azoic dyes: the colors are formed in the fiber by the combination of two components Reactive dyes: the dyes react chemically in the presence of alkali with the hydroxide group of cellulose which form the linkage between the two. Pigments: are not dyes in the true sense as they do not form chemical bonds but are held on the fiber mechanically Acid dyes: find their main application on wool, silk, polyamide, modified acrylic and regenerated protein fibers. They are applied by a dye liquor containing, sulphuric, formic, or acetic acid or ammonium sulphate. Disperse dyes are applied to polyamide and polyester fibers. They are colored organic substances with very low solubility in water which, during the course of dyeing are transferred from dispersion via monomolecular solution to the fiber. 2.1.6.2 Additives and other chemicals Apart from the chemicals and dyestuffs already mentioned the wet textile processing relies on a large variety of chemicals which support the processes or determine the characteristics of the final products such as salts (common salt, Glauber salt, soda ash), detergents, softeners, sequestrants, and so on. 2.1.7 Water There are several water use categories such as processing, potable purposes, utility and laboratory use. Each requires different water quality parameters. Process uses (preparation, dyeing, and finishing) include making concentrated bulk chemical stock solutions, treat solutions (bleaching, dye bath and finish mix) and numerous washes, hot and cold. Potable water is for drinking and cooking, Utilities use includes non-contact such as cooling water, boiler water, humidifier systems, equipment cleaning etc. The source of the water is important to consider as potable water is usually chlorinated which can have an effect on the shade or cause other problems in processing. Hardness also causes problems in boiler operations (scaling) or in humidifiers (blocking). 2.1.8 Energy Energy is mostly used in two forms, electrical to drive motors and engines, and thermal to heat process baths, calenders, singeing, etc. Sources of electricity are the national grid or generated by the company itself using diesel, coal and/or natural gas fueled generators. Thermal heat is usually provided in the form of steam, hot water or oil (in a closed system). Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 16 2.2 Cleaner Production Assessment Methodology The Cleaner Production assessment methodology is the most generally accepted methodology to reduce environmental impacts in a technical and economical manner. Cleaner Production as promoted by UNEP/UNIDO can be defined as follows: Cleaner Production holistic approach is a preventive, integrated strategy that is applied to the entire production cycle to: Increase productivity by ensuring a more efficient use of raw materials, energy and water; Promote better environmental performance through reduction at source of waste and emissions; Reduce the environmental impact of products throughout their life cycle by the design of environmentally friendly but cost-effective products. Most crucial is that Cleaner Production is preferred over relying on end-of-pipe pollution controls, and has to be regarded higher in hierarchy; going beyond pollution prevention and reducing quantities of Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 17 waste and eliminate part of the pollutants. Especially important is that Cleaner Production encompasses production processes and management procedures thereby entailing less use of resources than conventional technologies and also generates less waste and smaller amounts of toxic or other harmful substances. It emphasizes the human and organizational dimensions of environmental management, including good plant operation to avoid deliberate or accidental discharges. At the same time cleaner production is not claiming to cope with all environmental problems and still some treatment and disposal of remaining wastes will be required. Appropriate treatment systems must be designed and installed to achieve acceptable emissions levels. However, when starting with appropriately implementing preventive, process-integrated (Cleaner Production) measures, most likely the scale of operation for the treatment and disposal of remaining wastes can be (much) smaller, and thereby decreasing related investment and operating costs. The CP-assessments shall focus on the major inefficiencies in the process to contribute to improved performance of the companies (and thereby strengthening its competitiveness) and decreasing environmental impact (higher consumption efficiency (raw materials, water and energy and lower emissions) without decreasing the quality (specifications) of its products and potential intangible benefits (positive effects on occupational, health and safety conditions). The CP-assessments methodology is generic and can be applied in each type of enterprise, irrelevant which kind of industrial sector or even services (like tourism, hotels, hospitals, buildings, offices) and also irrelevant for the country. The methodology is standard, oriented around the 3 basic questions (where (input/output data) why (cause analysis) how (option generation)), but logically the actual issues to cope with during material balancing, cause analysis and the potential improvement areas will be sector specific and have to be even tailored to the specific conditions of the client (its specific products, the organizational structure, the culture, the local institutional and regulatory setting, etc.). Figure 1: cleaner production techniques Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 18 Although the methodology relies on a thorough analysis followed by generating options using the CP techniques companies and especially SMEs prefer technological options and often jump to the conclusion that the answer to their problem is buying new equipment. Often the choice is made without improving underlying problems such as low workers awareness and skills. A way to start improving this is to involve company staff in the improvement process. Whereas the CP methodology starts by organizing an in-house CP team to execute the CP assessments and this team consist of amongst others the director, technicians and workshop managers, small improvement groups can be formed at the workshop level focusing on reducing the use of resources. In order to encourage workers monthly consumption figures can be posted in the workshop showing the reduction in consumption. Off course measuring and controlling process parameters is important for raising awareness. Figure 2: general cycle of the CP assessment Phase 1: preparation Prior to the actual assessment some preconditions have to be established in order to enable the assessment activities. The most important condition is to raise the awareness of the management and to secure their commitment. A CP assessment team is than assembled in order to gather data, mobilize the knowledge already present as well as having the authority to implement improvement while assessing the situation. Selecting the right members for the team is an important activity. Establishing the baseline performance using historical data will indicate the starting point of the assessment. Phase 2: initial assessment In the initial assessment the CP team prepares the flow diagram in order to identify the location of the inefficiencies . The walkthrough is meant to verify the actual situation on the work floor and to identify the causes of the inefficiencies as much as possible. Obvious improvements identified during the walkthrough can be implemented immediately. Phase 3: detailed assessment Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 19 In the detailed assessment material and energy balances are established to quantify the flows, losses and inefficiencies. A thorough cause analysis of these inefficiencies will generate a comprehensive number of CP options covering equipment, technology, workers, recycling and resources. Phase 4: feasibility studies For those options requiring investments a feasibility study is done to establish the technical and economic feasibility as well as the environmental benefits. In principle the economic criteria for an investment are depending on the companys financial situation or mission but three years is generally accepted as a payback time. Phase 5: Implementation An implementation plan is needed to guide the implementation of options. The planning can depend on several issues such as availability of equipment, budgeting, downtime due to maintenance or renovation. When implemented the option has to be monitored and evaluated to ensure performance is met and assumptions checked. Integrating CP into the management structure should ensure continuous improvement and can be a start for establishing the environmental management system. 2.2.1 Basic CP assessment Depending on the status of the factory in terms of management and technology a CP assessment can be executed in several ways. When the awareness of the factory management and staff is low, equipment is old, metering is missing, SOPs do not incorporate efficient use of resources, no environmental management system exists, the first step to instill improvements is the basic CP assessment. In this type of assessment the obvious options are identified and their benefits calculated. Obvious options concern the (almost) visually present signs of waste and leakages whose volumes and costs are underestimated. Obvious options are mostly in the order of improvement control of parameters, improvement maintenance, improvement handling of resources, recycling and reusing and so on. Obvious options hardly require thorough analysis and lengthy measuring periods to prove their economic and environmental feasibility. Implementation is overall speaking also relatively easy. The next step would be an in-depth assessment which incorporates a more complex options usually technology changes and product changes. In-depth assessments have on average a higher requirement regarding metering, management, financing. 2.3 Pre-Assessment and Walkthrough Assessment Prior to the visit of the international consultants the factory is informed on the objectives of the project and some relevant information is obtained. Gathering this information has several purposes, first it is used by the consultants to determine the general performance of the factory (although this still has to be related to the actual process conditions at the later stage) and also it raises the awareness of the factory management on issues such as resource consumption related to production output. It also prepares the relevant factory staff for the objectives of and possible questions raised during the walkthrough. During the walkthrough the international consultants (on most occasions this were the (co)project manager, mechanical engineer, textile engineer) together with the local service providers and Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 20 factory staff visited all relevant workshops, storages and other supporting activities. The general approach is that after the initial discussion with the management the team is split into two groups in which one group focuses on the textile processing and the other on the utilities. During the walkthrough specific questions are raised which in principle should clarify the level of (resource) management and feasibility of possible options. These options are considered to be obvious for the teams and factory staff and concern improvements in the field of standard operating practices, maintenance, recycling and reusing, equipment modification. After visiting the production site a more detailed discussion has taken place and the action plan has been established. In the action plan most relevant improvement options have been listed which need further data collection and analysis. Apart from the cleaner production related issues also other issues were assessed such as OHS (occupational health and safety), WASH (water availability, safety and hygiene), EMS (environmental management system) and the chemical inventory regarding banned chemicals took place. 2.4 Collection of Data & Analysis General data needs to be collected to develop the baseline performance (or KPI) of the resource consumption such as for water liter/kg textile processed, electricity kWH/kg, steam in kg/kg, and so on. This baseline performance (or KPI) is used to quantify the overall improvement of the resource efficiency. In the case industry indicators are available these are used to compare with the factory indicators in order to stress the importance of and illustrate the feasibility of improving. Specific data is collected which should contribute to the calculation of the performance of an activity which has been identified during the walkthrough. For example is lacking insulation of the steam pipe is observed the temperature at the surface should be measured, the diameter of the pipe, the length etc. From experience the optimal surface temperature of an insulated pipe can then be used to calculate the potential heat saving and cost. Eliminating a wash in a dyeing process saves the volume of the bath and for recycling condensate is the volume and the temperature is relevant. See chapter 4 for further requirements of data collection and measurements. The local service providers have the most relevant mobile measuring equipment to measure temperature, humidity, electricity etc. In case when these equipment is insufficient and factory meters are lacking data has to be generated using equipment characteristics such as pump volumes and operation time for example to establish the total water pumped from the deep wells. For the analysis of the causes of waste in principle the team investigates whether the level of staff can be improved, equipment can be modified, waste streams can be reused, parameters better controlled. Based on this analysis options are generated. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 21 2.5 General Issues Identified 2.5.1 Commitment Overall speaking and when talking about the assessment the commitment was good. In few cases the assessment took more time as management was reluctant in allowing measurements to take place and data shared. In the end the results of most assessments can be considered good. In the 6 months implementation period most companies implemented the majority of options as identified for CP, WASH, EMS and OHS. 2.5.2 Metering Resources and especially water are in general not metered. In case metering takes place the data is not collected or analyzed (as in related to production output). Meters in the factory do not appear to be calibrated on a regular basis. As a consequence most meters appear neglected and un-serviced except for the meters on the wastewater treatment facilities. 2.5.3 Access to the factory and or facilities During the visits of the international consultants no restrictions were observed and all questions were answered freely and candidly. During the assessment however some limitations in obtaining data were observed for example when the stack has not sampling hole or when the factory has not a significant down time to establish pressurized air losses in the system. 2.5.4 EMS Other than the basic waste management procedures hardly any environmental management systems are operative in the textile industry. Establishing the CP team was for most companies the first step in establishing an organizational structure to address environmental issues. 2.5.5 WASH Overall speaking the quality of the drinking water and the number of toilets for men and women are considered sufficient. Some companies provide cold water and rehydration pills when temperatures exceed certain limits. 2.5.6 Chemical inventory and banned chemicals All factories visited have signed compliance statements regarding banned chemicals as well as asked these from their suppliers. Some chemical inventories can be improved especially when it concerns sub stores (working quantities in the factory). In the main storage MSDS and emergency equipment is available but missing in the sub stores. Handling and spill control can be improved. Personal protection equipment and especially safety boots and aprons in the wet section can be improved in few companies. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 22 2.5.7 Effluent Treatment Plant (ETP) All companies involved in this project do treat the wastewater using a biological treatment. In few cases the ETP was complimented with a chemical and a color treatment. Due to expansion a few companies were confronted with undersized ETPs and noncompliance can be expected at these sites. Wastewater reduction should be a priority for these companies and this can be achieved through water consumption reduction. 2.6 Debriefing of Cleaner Production Report After preparation the draft Cleaner Production report the findings are discussed with the company staff. The debriefing has the following topics: The overall consumption figures Consumption figures related to production output General observations regarding consumption figures, level of technology, management, scope for improvement, OHS (including chemicals), WASH and EMS and the Effluent Treatment Plant Options separated in process and utilities, investment, economic benefits and environmental benefits Conclusions, change in KPIs when options are implemented Most debriefings were well received and lead to interesting discussions between management and factory staff and service providers. In some cases the debriefing discussions lead to an expansion of number of options and improved understanding of previously rejected options. 2.7 Preparation and Submission of Report After debriefing company management and staff can submit comments and suggestions for the report. After these comments are incorporated the report is finalized and submitted to IFC. 2.8 Preparation of Action Plan In order to facilitate the monitoring of the implemented options taken by the factory local consultants prepared a monitoring format in consultation with IFC and International team. Throughout the 6 months monitoring period, that action plan sheet is used to capture the progress. 2.9 Consultants Visit Details The local consultant group prepared a visit calendar prior to the actual monitoring visit. The allocated visit for each factory was total 6 at a monthly basis. Prior communications had been done for a suitable visit for factories and action plan sheets and any other relevant documents had shared with factory CP team prior to visits. During visits, the main highlight were to capture the progress against each CP option stated in the final report and collect validation documents from factory CP team members. Necessary communications were done in between visits. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 23 2.10 Capacity Building of Local Consultants At the start of the project the local consultants received training on how to implement the assessment. The training consisted of two parts, a classroom training and hands-on training at 6 companies. The class room training consisted of modules concerning: General CP training and exercises Textile engineering Mechanical Engineering in textile processing Chemical engineering in textile processing Electrical engineering in textile processing For OHS, EMS and WASH self-explaining worksheets have been prepared which have been discussed with the local service providers designated staff. Prior to the start of the project the local service providers have received training in WASH and water footprint calculations. During the hands-on training at the 6 companies the local service providers learned to identify options, learned how to calculate data when (factory) meters are absent, consultancy skills, etc. All items were thoroughly discussed and the approach tailored to the local situation. After the 6 company visits the complete team was gathered in the class room to evaluate the visits and develop the action plans. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 24 3 Cleaner Production Implementation 3.1 General Overview 50 companies participated in the basic CP assessments. The type of activities in the wet processing section are dyeing (yarn, knit, woven) and washing (garments and denim). Production output and number of workers are listed to illustrate the size of the wet processing activities. # Factory name Type of factory Wet process capacity in ton/month unless specified otherwise Working days/year Number of workers (wet process only) 01 Unicom Textile Yarn dyeing and woven dyeing 425 340 250 02 Textown Textile Knit dyeing 312 340 208 03 Ring Shine Textile Yarn dyeing 1,841 340 1,726 04 HR Textile Knit dyeing 482 340 271 05 Noman Terry Towels Yarn dyeing & towel production 1,870 340 670 06 ARS Washing Ltd. Washing 781,000 pcs/month 340 95 07 Abanti Knit dyeing 700 340 410 08 Fariha Knit dyeing 1,133 340 445 09 Graphics Knit dyeing 340 340 302 10 Iris Fabrics Knit dyeing 3,309 340 253 11 Windy Washing Washing 975,000 pcs/month 340 100 12 Karooni Textile Knit dyeing 538 340 364 13 Norban Comtex Knit dyeing 285 340 330 14 Mondol Knit Tex Knit dyeing 240 340 100 15 Evince Textile Dyeing 270 340 375 16 Reedisha Knit dyeing 480 340 480 17 Aman Knit dyeing 720 340 459 18 Thermax Yarn dyeing 300 350 862 19 EOS Fabric dyeing 600,000 m/month 350 194 20 Regency Washing 300 297 660 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 25 21 Intramex Yarn, woven & knit dyeing 480 296 1,041 22 Paramount woven dyeing, yarn dyeing Fabric: 1.3 million m/ year Yarn: 720 252 231 23 Etafil accessories LTD. (yarn dyeing unit of Tamishna) Yarn dyeing 960 340 174 24 Russel Washing 600,000 pcs/month 296 18 25 Maxcom Denim washing 15,000 pcs/ month 326 101 26 JM Fabrics Knit dyeing 390 352 100 27 Genesis Washing 600,000 pcs/month 282 76 28 Libas Knit dyeing 480 313 355 29 ATS Denim washing Garments: 650,000 pcs/month Denim: 300,000 pcs/month 302 30 30 Taqwa Washing 360 340 197 31 Pioneer Sweater garments washing 50,000 pcs/day 296 607 32 Partex Denim Denim washing, dyeing 1,000 360 210 33 Bengal Hurricane Knit dyeing, printing 600 300 244 34 Newage Textiles Knit dyeing 360 350 250 35 Denim Expert Washing 180 290 168 36 Unifill Composite Woven dyeing 630 300 343 37 Fashion Forum Washing 425 300 350 38 Esquire Knit Knit dyeing 524 286 660 39 Meghna Knit Knit dyeing 632 345 350 40 Modele De Capital Washing 425 300 380 41 East West Suiting Sweater garments washing 10o 300 53 42 Envoy Textiles Woven dyeing 1,050 355 163 43 P. N. Composite Knit dyeing & washing 352 352 251 44 Saiham Knit Knit dyeing 300 300 164 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 26 45 Universal Jeans Denim washing 360 300 424 46 Jeans 2000 Denim washing 300 300 215 47 Best Wool Washing 185 302 11 48 FCI Denim & twill dyeing and washing 163 290 43 49 Super Knitting yarn dyeing and knit dyeing 245 300 153 50 Purbani Knit dyeing 402 345 64 3.2 Individual Factory Implementation 3.2.1 Unicom textile This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 15 233,191 157,496 0 0 0 KPIs Parameter Before after Reduction (%) Water 193 l/kg n/a l/kg 0 Steam 11.95 kg/kg n/a kg/kg 0 Electricity 3.95 kWh/kg n/a kWh/kg 0 NG 1.4 m3/kg n/a m3/kg 0 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 0 0 0 0 0 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 27 OHS 6 3 Chemical Inventory 1 1 EMS 4 1 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,059 2,059 Due to extensive expansions and renovations, no options have been implemented in the monitoring period. 3.2.2 Textown This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 156,773 70,861 7 53,149 18,727 KPIs Parameter Before after Reduction (%) Water 104 l/kg 101 l/kg 3 Gas 1.23 m3/kg 1.12 m3/kg 9 Steam 4.00 kg/kg 3.75 kg/kg 7 Electricity 2.01 kWh/kg 1.90 kWh/kg 5 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 813,000 8,465 354,000 409,319 802 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 6 5 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 28 Chemical Inventory 1 1 EMS 4 1 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,678 1,655 Some major CP options like exhaust heat recovery boiler installation has not been done due to time constraints yet. The factory team is positive that these options will be implemented in the near future. 3.2.3 Ring Shine Textile This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 11 649,511 301,401 10 19,916 150,315 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 0 328,864 533,000 752,075 1,474 KPIs Parameter Before after Reduction (%) Water 144 l/kg 126 l/kg 13 Gas 820 m3/kg 784 m3/kg 4 Steam 13 kg/kg 13 kg/kg 0 Electricity 2 kWh/kg 1.6 kWh/kg 2 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 10 10 Chemical Inventory 1 1 EMS 3 3 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 29 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 7,288 6,550 Due to the delay in top level decision making, one major option had not been initiated. Some options have not been implemented for the full 100% and completion is ongoing. 3.2.4 HR Textile This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 53,191 63,670 4 18,200 26,543 KPIs Parameter Before after Reduction (%) Water 113 l/kg 112 l/kg 1 Gas 1.61 m3/kg 1.57 m3/kg 2 Steam 4.16 kg/kg 2.07 kg/kg 50 Electricity 2 kWh/kg 1.52 kWh/kg 0.2 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 9,497,000 24,733 12,000 150,366 295 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 8 5 Chemical Inventory 1 1 EMS 2 0 WASH 3 3 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 30 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,620 1,607 Due to changes in factory CP team members, most of the CP options have not been initiated. 3.2.5 Noman Terry Towels This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 7 20,366 42,304 6 8,968 7,190 KPIs Parameter Before after Reduction (%) Comments Water 74.7 l/kg 74.2 l/kg 1 For total wet process production (yarn and towel dyeing) Gas 918 m3/kg 916 m3/kg 0.2 For total NG consumption Steam 2.54 kg/kg 2.54 kg/kg 0 Towel Dyeing (In Winch) Electricity 3.27 kWh/kg 3.26 kWh/kg 0.1 total electricity consumption(process and Utility) Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 0 6,087 94,000 69,992 136 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 2 1 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 31 Chemical Inventory 1 1 EMS 2 2 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 3,185 3,167 Noman Terry towels Ltd already implemented ISO14000 environmental management system and various improvement options. Being a role model for energy and water saving and having very positive on CP approach, the changes are minimal but due to the size of production still constitute a large volume. A follow up activity such as an in-depth assessment would be appropriate to develop more significant and less obvious options. 3.2.6 ARS Washing Ltd. This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 13 35,940 43,519 6 1,733 21,115 KPIs Parameter Before after Reduction (%) Water 195 l/kg 173 l/kg 11 Gas 458 m3/kg 450 m3/kg 2 Steam 2.67 kg/kg 2.67 kg/kg 0 0.126 kg/pcs 0.126 kg/pcs 0 3.25 kg/kg 3.22 kg/kg 1 Electricity 0.013 kWh/kg 0.013 kWh/kg 0 0.114 kWh/piece 0.114 kWh/piece 0 0.67 kWh/kg 0.63 kWh/kg 6 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 32 209,000 94,287 86,000 25,247 104 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 9 7 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,059 1,799 During the project top level management and working team changed which hampered the execution, a few options are yet to be implemented. 3.2.7 Abanti This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 103,724 116,007 7 12,180 51,717 KPIs Parameter Before after Reduction (%) Water 225 l/kg 224 l/kg 0.4 Gas 1,724 m3/kg 1,639 m3/kg 4 Steam 10.64 kg/kg 10.07 kg/kg 5 Electricity 6.66 kWh/kg 6.58 kWh/kg 3 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 713,000 47,240 366,000 550,889 1080 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 33 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 6 5 Chemical Inventory 1 1 EMS 3 3 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 3,695 3,681 The factory management and staff is positive on CP approach, however due to time and financial constraints some major options are yet to be implemented. 3.2.8 Fariha This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 12 235,129 145,213 6 6,525 30,884 KPIs Parameter Before after Reduction (%) Water 61 l/kg 53 l/kg 13.11 Gas 1595 m3/kg 1582 m3/kg 0.81 Steam 5.63 kg/kg 5.62 kg/kg 0.20 Electricity 1.54 kWh/kg 1.53 kWh/kg 0.64 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 87,000 86,102 55,500 119,123 233 Policies implemented Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 34 Options Recommended & Agreed (nos.) Implemented (nos.) OHS 5 4 Chemical Inventory 1 1 EMS 2 1 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2160 1907 A few major options are yet to be implemented as they are awaiting top level management decision. 3.2.9 Graphics This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 8 120,585 65,714 5 - 12,210 KPIs Parameter Before after Reduction (%) Water 134 l/kg 134 l/kg 0 Gas 2431 m3/kg 2405 m3/kg 1 Steam 15.89 /kg 15.89 Kg /kg 0 Electricity 2.37 kWh/kg 2.23 kWh/kg 2 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 0 4,364 98,000 96,877 190 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 35 OHS 7 6 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,992 2,992 The management approved the implementation of the no cost/low cost options but the other more major options are yet to be implemented. 3.2.10 Iris Fabrics This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 8 196,247 94,241 6 695 32,500 KPIs Parameter Before after Reduction (%) Water 66 l/kg 54 /kg 18 Gas 805 m3/kg 767m3/kg 5 Steam 6.03 kg/kg 6.01kg/kg 0.3 Electricity 0.82 kWh/kg 0.747 kWh/kg 9 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 118,000 52,327 410,000 219,616 430 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 36 OHS 3 3 Chemical Inventory 1 1 EMS 1 1 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,333 1,179 Apart from a few major options, the factory team implemented most of the options. 3.2.11 Windy Washing This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 8 7,681 17,138 7 1,135 3,161 KPIs Parameter Before after Reduction (%) Water 60 l/kg 59 l/kg 2 (denim) 15.9 l/kg 14.77 l/kg 7 (twill) Gas 258 m3/kg 258 m3/kg 0.1 Steam 2.57 kg/kg 2.57 kg/kg 0 Electricity 0.19 kWh/kg 0.19 kWh/kg 0 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 0 4,822 20,150 2,500 13 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 5 5 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 37 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 494 480 This is a rather small set up factory and the factory team implemented most of the options. 3.2.12 Karooni Textile This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 11 194,687 88,723 3 13,913 KPIs Parameter Before after Reduction (%) Water 52.8 l/kg 51.09 /kg 3.23 Gas 1,547 m3/kg 1,516 m3/kg 1.92 Steam 2.96 kg/kg 2.65 kg/kg 3.65 Electricity 0.40 KWh/kg 0.40 KWh/kg 0 1.17 kWh/kg 1.16 kWh/kg 0.7 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 2,086,000 18,510 52,000 188,505 369 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 6 3 Chemical Inventory 1 1 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 38 EMS 3 1 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 3,384 3,330 Most options have been implemented but for implementing some major options top level management decision is pending. 3.2.13 Norban Comtex This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 95,364 39,694 4 15,061 3,879 KPIs Parameter Before after Reduction (%) Water 161 l/kg 159 l/kg 1 Gas 1.94 m3/kg 1.93 m3/kg 0.5 Steam 7.38 kg/kg 7.38 kg/kg 0 Electricity 2.54 kWh/kg 2.52 kWh/kg 0.5 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 0 4,442 35,000 27,337 53 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 7 7 Chemical Inventory 1 1 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 39 EMS 3 3 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,438 1,425 The major option implementations are waiting for high level management decisions. 3.2.14 Mondol Knit Tex This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 176,878 95,710 8 20,456 27,664 KPIs Water 380 l/kg 373 l/kg 4 Gas 2.49 m3/kg 2.40 m3/kg 3 Steam 8.92 kg/kg 8.76 kg/kg 2 Electricity 0.334 kWh/kg 0.334 kWh/kg 0 2.39 kWh/kg 2.29 kWh/kg 4 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 329,000 24,592 228,000 190,895 374 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 5 4 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 40 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,711 2,665 The factory management is positive on the CP approach and is implementing options gradually as per their priority. Most options have been implemented 3.2.15 Evince Textile This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 227,846 123,601 5 6,189 5,458 KPIs Parameter Before after Reduction (%) Water 257 l/kg 252 l/kg 2 Gas 3178 m3/kg 3160 m3/kg 0.6 Steam 8.16 kg/kg 8.06 kg/kg 1 Electricity 2.71 kWh/kg 2.71 kWh/kg 0 4.76 kWh/kg 4.72 kWh/kg 1 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 200,000 9,596 139,700 64,625 127 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 6 4 Chemical Inventory 1 1 EMS 2 2 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 41 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 3,673 3,645 Implementing the more major and investment requiring options are waiting for high level management decision. 3.2.16 Reedisha This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 14 251,575 135,324 9 - 30,007 KPIs Parameter Before after Reduction (%) Water 183 l/kg 174 l/kg 3 Gas 7769 m3/kg 7713 m3/kg 1 Steam 12.24 kg/kg 12.18 kg/kg 0.50 Electricity 4.49 kWh/kg 4.36 kWh/kg 3 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 980,000 47,786 591,000 263,313 516 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 5 5 Chemical Inventory 1 1 EMS 3 3 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 42 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 5,390 5,249 Management started implementing the no cost options and will implement the remaining options in the near future. 3.2.17 Aman Tex This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 52,833 28,209 9 30,786 11,085 KPIs Parameter Before after Reduction (%) Water 139 l/kg 133 l/kg 4 Gas 247 m3/kg 203 m3/kg 18 Steam 8.84 kg/kg 8.76 kg/kg 1 Electricity 0.486 kWh/kg 0.486 kWh/kg 0 2.58 kWh/kg 2.50 kWh/kg 3. Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 397,000 33,073 396,000 219,486 430 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 4 Chemical Inventory 1 1 EMS 2 2 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 43 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,295 2,200 The factory team has implemented most of the options within the monitoring period which showcases their commitment to the CP approach. 3.2.18 Thermax This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 28,112 42,675 5 1,795 12,907 KPIs Parameter Before after Reduction (%) Water 121 /kg 114 l/kg 6 Gas 5220 m3/kg 5145 m3/kg 1 Steam 1.82 kg/m 1.82 kg/m 0 7.85 Kg/kg 7.85 Kg/kg 0 29 kg/kg 28.67 kg/kg 0.5 Electricity 2.26 kWh/kg 2.26 kWh/kg 0 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 756,000 96,205 0 415,510 815 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 4 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 44 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 5,189 5,070 The factory has a good set up and is positive on the CP approach. A few options are yet to be implemented. 3.2.19 EOS Textile This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 5 2,764 29,211 4 4,791 8,023 KPIs Parameter Before after Reduction (%) Water 25.7 l/m 25.7 l/m 0 Gas 95,259 m3/kg 93,866 m3/kg 1.5 Steam 4.13 kg/m 3.92 kg/m 5 Electricity 1.40 kWh/kg 1.37 kWh/kg 2 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 245,000 0 157,700 67,840 150 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 4 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 45 Chemical Inventory 1 1 EMS 3 3 WASH 2 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 687 687 As the factory can be a role model for water and energy saving actions, the factory team initiated most of the options within a short time. 3.2.20 Regency This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 9 10,609 52,741 7 8,423 67,025 KPIs Parameter Before after Reduction (%) Water 98 l/kg 91 l/kg 6 Gas 440 m3/kg 310 m3/kg 30 Steam 1.15 kg/kg 1.15 kg/kg 0 Electricity 0.474 kWh/kg 0.474 kWh/kg 0 (washing) 0.72 kWh/kg 0.69 kWh/kg 4 (total) Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 0 42,574 115,500 419,327 481 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 4 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 46 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,459 2,357 A proactive team took effective action on implementing CP options and almost all major actions are done within first 6 months. 3.2.21 Intramex This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 15 143,761 82,804 2 2,123 12,691 KPIs Parameter Before after Reduction (%) Water 115 litre/kg 115 litre/kg 0 (knit) 100 litre/kg 100 litre/kg 0 (yarn) 38 litre/meter 38 litre/meter 0 (woven) 21 litre/kg 21 litre/kg 0 (twill) Gas 2660 m3/kg 2631 m3/kg 1 Steam 2.76 kg/kg 2.76 kg/kg 0 (knit) 2.91 kg/meter 2.91 kg/meter 0 (woven) 4.66 kg/kg 4.66 kg/kg 0 (yarn) 19.57 kg/kg 19.42 kg/kg 1 (total) Electricity 0.285 kWh/kg 0.285 kWh/kg 0 (knit) 1.87 kWh/meter 1.87 kWh/meter 0 (woven) 3.88 kWh/kg 3.88 kWh/kg 0 (yarn) 3.73 kWh/kg 3.66 kWh/kg 2 (overall) Resource and environmental benefits Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 47 Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 494,000 181 216,300 95,306 187 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 5 5 Chemical Inventory 1 1 EMS 3 2 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,830 1,830 Most of the options are waiting management decision. 3.2.22 Paramount This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 12 177,637 91,152 4 83,134 23,943 KPIs Parameter Before after Reduction (%) Water 95.2 litre/kg 95.2 litre/kg 0 (woven) 8.2 litre/meter 8.2 litre/meter 0 (yarn) Gas 2,414 m3/kg 2,356 m3/kg 2 Steam 1.01 kg/meter 1.01 kg/meter 0 (yarn) 0.023 kg/kg 0.023 kg/kg 0 (woven) Electricity 1.73 kWh/kg 1.73 kWh/kg 0 (yarn) 0.09 kWh/meter 0.09 kWh/meter 0 (woven) 4.99 kWh/kg 4.82 kWh/kg 3 (total) Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 48 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 528,000 0 1,110,000 381,921 749 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 6 6 Chemical Inventory 1 1 EMS 3 2 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 3,133 3,133 The factory has implemented a few options and incurred a significant investment, a lot more options are pending management decision. 3.2.23 Etafil This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 13 320,675 198,611 6 21,284 32,649 KPIs Parameter Before after Reduction (%) Water 101 l/kg 100 l/kg 1 Gas 3.05 m3/kg 3.05 m3/kg 0 Steam 9.9 kg/kg 9.7 kg/kg 2 Electricity 4 kWh/kg 3.69 kWh/kg 8 Resource and environmental benefits Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 49 Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 153,3000 4,957 668,300 352,989 691 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 5 4 Chemical Inventory 1 1 EMS 3 1 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 4,045 3,972 Although there is a significant opportunities to improve, CP needs more attention and commitment from top level management to speed up the implementation. 3.2.24 Russel This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 5 4,098 6,903 3 10,235 6,048 KPIs Parameter Before after Reduction (%) Water 22 l/kg 18 l/kg 16.23 Gas 278 m3/kg 265 m3/kg 4.68 Steam *NAV *NAV *NAV Electricity **NAV **NAV **NAV NAV: Not available Resource and environmental benefits Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 50 Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 62,000 14,814 4,000 37,152 75 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 3 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 672 639 Russel is a small set up and the factory team is positive on implementation. 3.2.25 Maxcom This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 7 3,137 28,055 6 36,834 18,773 KPIs Water 116 l/kg 94 l/kg 19 Gas 475 m3/kg 467 m3/kg 2 Steam 1.21 kg/kg 0.80 kg/kg 30 Electricity 0.86 kWh/kg 0.85 kWh/kg 1 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 1,685,000 102,826 5,600 29,827 58 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 51 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 2 Chemical Inventory 1 1 EMS 3 3 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,716 1,406 The factory is positive on CP approach and has taken action on implementing the options . In fact they are going through expansion works which somehow enabled them to incorporate a few options. 3.2.26 JM Fabrics This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 11 112,951 59,012 8 99,795 46,558 KPIs Parameter Before after Reduction (%) Water 133 l/kg 123 l/kg 7 Gas 256 m3/kg 228.6 m3/kg 11 Steam 10.30 kg/kg 6.79 kg/kg 34 Electricity 0.25 kWh/kg 0.24 kWh/kg 4 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 3,277,000 11,340 139,200 616,290 1,208 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 52 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 5 4 Chemical Inventory 1 1 EMS 3 2 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,484 1,452 The factory team is positive on CP approach and has taken good action on implementation. 3.2.27 Genesis This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 5 2,698 21,223 2 11,556 6,223 KPIs Parameter Before after Reduction (%) Water 139 l/kg 120 l/kg 14 Gas 721 m3/kg 712.6 m3/kg 1 Steam 5.31 kg/kg 5.27 kg/kg 1 Electricity 1.52 kWh/kg 1.49 kWh/kg 2 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 126,000 60,279 83,000 27,706 54 Policies implemented Options Recommended & Implemented (nos.) Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 53 Agreed (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,828 1,614 The factory has a good set up and showed their interest in implementing a few major options. 3.2.28 Libas This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 15 60,200 74,801 9 24,507 17,869 KPIs Parameter Before after Reduction (%) Water 180 l/kg 175 l/kg 2.76 Gas 932 m3/kg 874 m3/kg 6.22 Steam 5.20 kg/kg 4.50 kg/kg 12.56 Electricity 1.29 kWh/kg 1.27 kWh/kg 1.55 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 2,637,000 24,795 63,900 240,859 472 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 6 6 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 54 Chemical Inventory 1 1 EMS 3 2 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,649 2,587 The implementation of the options are delayed due to some changes in management and to fulfill other priorities. Although they have started working late on implementing the options the progress is good. 3.2.29 ATS This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 6 915 1,542 4 814 318 KPIs Parameter Before after Reduction (%) Water 13 l/kg 10.58 l/kg 19 Gas 721 m3/kg 721 m3/kg 0 Steam 2.60 kg/kg 2.60 kg/kg 0 Electricity 3.333 kWh/kg 3.331 kWh/kg 0.1 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 0 1,409 1,000 0 1 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 55 Chemical Inventory 1 1 EMS 2 2 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 45 40 As the factory is a small set up, the options were limited. However the factory team is committed and is gradually implementing the options. 3.2.30 Taqwa This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 16 73,705 70,572 6 0 8,803 KPIs Parameter Before after Reduction (%) Water 151 l/kg 91 l/kg 40 Gas 1398 m3/kg 1366 m3/kg 2 Steam 7 kg/kg 6.37 kg/kg 9 Electricity 1.87 kWh/kg 1.86 kWh/kg 0.5 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 1,925,000 185,060 10,800 155,065 304 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 1 Chemical Inventory 1 1 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 56 EMS 3 0 WASH 3 1 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,554 1,015 Some good opportunities have been explored and the factory team is positive on implementation. Still the progress is not good due to delayed response from top level on the implementation of the major opportunities. 3.2.31 Pioneer Knitwear This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 8 115,469 24,826 3 17,949 2,0565 KPIs Parameter Before after Reduction (%) Water 12 l/kg 6 l/kg 50 Gas 1903 m3/kg 1892 m3/kg 0.6 Steam 5.88 kg/kg 5.87 kg/kg 0.1 Electricity 0.30 kWh/kg 0.30 kWh/kg 0 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 4,000 18,924 0 25,568 50 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 3 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 57 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 196 143 A good set up and the factory team is gradually taking care of the options. 3.2.32 Partex denim This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 9 63,492 110,909 5 1,115 40,934 KPIs Parameter Before after Reduction (%) Water 76 l/kg 37 l/kg 51 Gas 2665 m3/kg 2558 m3/kg 4 Steam 9.9 kg/kg 4.87 kg/kg 50 Electricity 4 .05 kWh/kg 3. 97 kWh/kg 2 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 238,000 53,122 367,500 535,041 1,049 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 2 2 WASH 3 3 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 58 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,824 1,817 The implemented options have significantly reduced the water consumption. However due to other priority issues, the progress of implementation can be considered slow. 3.2.33 Bengal This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 14 71,084 47,554 9 18,243 9,144 KPIs Parameter Before after Reduction (%) Water 109 l/kg 109 l/kg 0 Gas 1289 m3/kg 1264 m3/kg 2 Steam 5.6 kg/kg 5.59 kg/kg 3.5 Electricity 1.17 kWh/kg 1.13 kWh/kg 3.4 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 486,000 2,928 192,200 122,162 239 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 59 Blue water footprint 2,237 2,237 Some actions have been taken but there are major options which still have not been initiated and are pending management decision. 3.2.34 Newage This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 16 143,712 91,633 3 1,066 19,296 KPIs Parameter Before after Reduction (%) Water 139 l/Kg 48 l/Kg 65 Gas 5198 m3/kg 5099 m3/kg 2 Steam 1.73 kg/kg 1.68 kg/kg 3 Electricity 4.27 kWh/kg 4.20 kWh/kg 2 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 1,540,000 124,779 96,300 136,253 267 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 2 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,194 1,837 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 60 Due to lack of involvement of top management, the major options are awaiting implementation. 3.2.35 Denim expert This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 30,800 49,953 5 3,467 43,926 KPIs Parameter Before after Reduction (%) Water 144 l/kg 120 l/kg 17 Gas 546 m3/kg 528 m3/kg 3 Steam 1.20 kg/kg 1.00 kg/kg 12 Electricity 1.17 kWh/kg 1.02 kWh/kg 13 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 223,400 36,310 218,800 26,483 191 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 2 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 771 646 The factory team is very committed to the CP approach and has taken major steps for implementation. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 61 3.2.36 Unifill This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 16 91,616 65,872 7 16,137 13,076 KPIs Parameter Before after Reduction (%) Water 161.25 l/kg 156.68 l/kg 5 Gas 795 m3/kg 776 m3/kg 2 Steam 6.86 kg/kg 6.84 kg/kg 3 Electricity 0.68 kWh/kg 0.65 kWh/kg 4 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 282,000 2,187 184,500 118,726 233 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 2 Chemical Inventory 1 1 EMS 3 2 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,398 1,391 The management involvement in decision making is not very encouraging which is the reason that the implementation of options is behind schedule. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 62 3.2.37 Fashion Forum This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 14 138,010 61,460 9 139,719 23,761 KPIs Water 88 l/kg 72 l/kg 18 Gas 1176 m3/kg 1085 m3/kg 8 Steam 0.894 kg/kg 0.880 kg/kg 1.5 Electricity 0.97 kWh/kg 0.78 kWh/kg 20 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 247,000 32,956 711,000 335,517 658 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 4 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,585 1,504 The factory team is very positive on CP approach and has already taken good steps to implement majority of the options. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 63 3.2.38 Esquire Knit This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 12 98,464 51,300 9 6,396 22,509 KPIs Parameter Before after Reduction (%) Water 392 l/kg 376 l/kg 4 Gas 2042 m3/kg 1998 m3/kg 2 Steam 8.547 kg/kg 8.546 kg/kg 0 Electricity 3.38 kWh/kg 3.30 kWh/kg 2 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 7,000 50,909 417,800 250,197 493 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 5,503 5,377 The factory team and higher management are very committed on implementations and have already implemented the few major options. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 64 3.2.39 Meghna Knit This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 14 98,213 66,460 8 0 43,296 KPIs Parameter Before after Reduction (%) Water 181 l/kg 173 l/kg 4.19 Gas 1364 m3/kg 1223 m3/kg 10.34 Steam 8.5 kg/kg 8.2 kg/kg 2.74 Electricity 1.83 kWh/kg 1.81 kWh/kg 1.09 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 844,000 32,889 73,800 510,014 1,000 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 3 Chemical Inventory 1 1 EMS 3 0 WASH 3 2 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,542 2,457 The factory team started with implementing the no cost options and have planned to execute the rest within a short period of time. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 65 3.2.40 Modele de Capital This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 12 160,330 90,688 7 114,345 75,450 KPIs Parameter Before after Reduction (%) Water 172 l/kg 143 l/kg 17 Gas 1481 m3/kg 1286 m3/kg 13 Steam 8.40 kg/kg 8.30 kg/kg 0.2 Electricity 1.12 kWh/kg 1.05 kWh/kg 6 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 58,000 131,147 317,600 877,462 1,720 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 2 2 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,855 2,427 The factory team is very positive and committed on implementing the CP options. A few major options have already been implemented while the implementation of the others is in progress. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 66 3.2.41 East West This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 67,458 26,321 2 420 591 KPIs Parameter Before after Reduction (%) Water 38.6 l/kg 38.6 l/kg 0 Gas 2519 m3/kg 2514 m3/kg 0.2 Steam 4.2 kg/kg 4.2 kg/kg 0 Electricity 2.99 kWh/kg 2.98 kWh/kg 0.3 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 0 0 8,400 4,335 8 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 6 3 Chemical Inventory 1 1 EMS 3 1 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 474 474 The factory is dealing with some crisis due to inconsistent supply of natural gas and this is impacting their regular production negatively. Due to these issues, the factory team is yet to implement most significant options. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 67 3.2.42 Envoy This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 10 29,945 19,141 7 71,848 8,939 KPIs Parameter Before after Reduction (%) Water 65 l/kg 63. 64 l/kg 2 Gas 1,456 m3/kg 1,443 m3/kg 1 Steam 4.79 kg/kg 4.78 kg/kg 0.2 Electricity 4.05 kWh/kg 4.03 kWh/kg 0.5 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 87,000 25,293 133,800 117,080 229 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 3,970 3,924 The factory has a good set up and showcases some good examples of saving opportunities. The implementations are going on as per their priority rating. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 68 3.2.43 PN Composite This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 14 90,055 67,286 4 41,198 18,035 KPIs Parameter Before after Reduction (%) Water 91 l/kg 91 l/kg 0 Gas 2,276 m3/kg 2,189m3/kg 4 Steam 9.50 kg/kg 9.46 kg/kg 0.6 Electricity 2.37 kWh/kg 2.34kWh/kg 1.3 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 145,000 28,512 76,000 228,302 448 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 6 5 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,324 1,324 Despite of having good interest in the CP approach, the implementation of the options requires more commitment from top level management. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 69 3.2.44 Saiham Knit Composite This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 11 82,509 37,610 7 9,584 7,420 KPIs Parameter Before after Reduction (%) Water 217 l/kg 195 l/kg 10 Gas 2,481 m3/kg 2,437 m3/kg 2 Steam 48.4 kg/kg 48.3 kg/kg 0.1 Electricity 3.22 kWh/kg 3.125 kWh/kg 3 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 37,000 32,855 144,120 66,101 129 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 4 Chemical Inventory 1 1 EMS 2 2 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 2,342 2,232 The factory has a modern set up and the management is committed to implement CP options. A few major options are yet to be implemented and are awaiting management decision. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 70 3.2.45 Universal Jeans This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 11 79.076 117.368 5 70,157 115,977 KPIs Parameter Before after Reduction (%) Water 157 l/kg 154 l/kg 2 Gas 852 m3/kg 771.77 m3/kg 9 Steam 0.55 kg/kg 0.48 kg/kg 12 Electricity 3.56 kWh/kg 3.296 kWh/kg 7 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 238,000 10,343 991,500 299,034 586 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 4 Chemical Inventory 1 1 EMS 3 2 WASH 3 1 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 3,872 3,838 The factory team is very positive and higher level commitment is visible. The implementations have started and a good progress is shown. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 71 3.2.46 Jeans 2000 This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 11 118,711 99,065 4 54,765 8,595 KPIs Parameter Before after Reduction (%) Water 98 l/kg 98 l/kg 0 Gas 1,427 m3/kg 1,405 m3/kg 1.5 Steam 6.65 kg/kg 6.64 kg/kg 0.2 Electricity 1.96 kWh/kg 1.914 kWh/kg 2.4 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 62,000 0 128,000 57,755 113 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 4 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,289 1,289 The factory team is very positive and higher level commitment is visible. The implementations have started and a good progress is shown. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 72 3.2.47 Best Wool This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 9 138,962 44,669 8 388,624 16,139 KPIs Parameter Before after Reduction (%) Water 7.50 l/kg 5.0 l/kg 33 Gas 1,410 m3/kg 1,291m3/kg 8 Steam 2.19 kg/kg 2.18 kg/kg 0.5 Electricity 1.04 kWh/kg 1.025 kWh/kg 1 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 8,000 8,227 36,550 234,282 458 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 333 315 Despite having a small set up and limited options, the factory team has taken good steps to implement major options. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 73 3.2.48. FCI This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 5 2,794 14,555 3 3,562 8,444 KPIs Parameter Before after Reduction (%) Water 36.70 l/kg 36.70 l/kg 0 Gas 481 m3/kg 479.95 m3/kg 0.2 Steam 1.31 kg/kg 1.31 kg/kg 0.2 Electricity 2.16 kWh/kg 2.11 kWh/kg 2 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 4,000 0 77,000 5,967 75 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 380 380 Being a modern set up and a pioneer in implementing water and energy saving options, the factory team is working on implementing the limited options explored. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 74 3.2.49 Super Knitting This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 15 130,522 76,625 6 0 7,365 KPIs Parameter Before after Reduction (%) Water 188 l/kg 181 l/kg 4 Gas 1,705 m3/kg 1,685.90 m3/kg 1 Steam 11.11 kg/kg 11.03 kg/kg 1 Electricity 1.72 kWh/kg 1.688 kWh/kg 2 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 215,000 17,912 85,000 50,798 99 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 4 3 Chemical Inventory 1 1 EMS 3 0 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 1,958 1,898 Progress is slow and mainly the no cost options have been implemented. The factory CP team needs good support from top level management to implement major options. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 75 3.2.50 Purbani This chapter describes the results of the CP assessment and the implementation of the identified options and policies during the 6 months monitoring period. The tables list options identified in the CP assessment phase and implemented and investment identified and done and savings obtained. The Key Performance Indicators (KPI) lists the situation at the start and end of the monitoring phase. The resource and environmental savings have been obtained due to the implementation of the options. Number of policies regarding OHS, WASH, EMS and chemical inventory have been given versus implemented. The blue water footprint has been listed as the wastewater reduction is considered equal to water consumption reduction as only the volumes have been assessed. CP Report Options implemented Options developed Investment USD Savings USD/year Options implemented Investment USD Savings, USD 11 122,784 53,598 7 18,964 5,574 KPIs Parameter Before after Reduction (%) Water 175 l/kg 172 l/kg 2 Gas 2,885 m3/kg 2,862.52 m3/kg 1 Steam 11.90 kg/kg 11.40 kg/kg 4 Electricity 4.45 kWh/kg 4.414 kWh/kg 1 Resource and environmental benefits Steam Saving kg per year Water Saving (m3 per year) Electricity Saving per year (kWh/y) NG Saving (m3 per year) GHG Avoided in tonnes (CO2e) per year 271,000 10,593 109,320 77,956 153 Policies implemented Options Recommended & Agreed (nos.) Implemented (nos.) OHS 3 3 Chemical Inventory 1 1 EMS 3 3 WASH 3 3 Water footprint Parameter Before (m3/day) After (m3/day) Blue water footprint 3,527 3,496 While low cost/no cost options are already initiated, the factory team needs support from top management to execute other major options. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 76 3.3 Financial Impacts of the Pilot Project In the 50 CP company assessments 545 options were recommended which may incur an estimated total investment of 5,626,789 USD with which an total potential benefit of 3,605,020 USD can be obtained. The estimated payback was on average nineteen months. After a six month monitoring period it was concluded that 185 options (34% of the suggested/agreed recommendations) have been implemented with a total investment value of 1,592,909 USD and generating economic benefits of 768,020 USD per year. Simple payback of the investment is 2 years. 3.4 Resource Saving and Environmental Benefits Within the monitoring period 185 options out of 545 identified options have been implemented by the 50 companies which have generated the following resource savings and environmental benefits. Water consumption The 50 companies managed to reduce their water consumption with 1.97 million m3 which is over 5% of the original annual consumption 38.1 million m3. Of the 1.97 million m3 reduction 1.59 million m3 was obtained in the wet textile processing units. Natural gas The 50 companies managed to reduce their natural gas consumption with 10.3 million m3 which is approximately 3% of the original annual consumption 404 million m3. The corresponding financial value of the NG saving is 645,109 USD Electricity The 50 companies managed to reduce their electricity consumption with 10,389 MWh which is approximately 2% of the original annual consumption 288,284 MWh. Saving resource is equivalent to 1.64million USD per year. Steam The 50 companies managed to reduce their steam consumption with 34,389 ton which is approximately 1.33% of the original annual consumption 2,617,187 ton Greenhouse gases The 50 companies managed to reduce their greenhouse gases generation with 20,946 ton which is approximately 3% of the original annual generation of 794078 ton Wastewater The 50 companies managed to reduced their wastewater generation with 1.59 million m3 which is approximately 5% of the original annual generation of 28.9 million m3. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 77 3.5 Qualitative Changes Apart from the implementation of the options which yielded quantitative benefits also changes have been made which improved safety, working atmosphere etc. Most factories made positive changes in following areas: Improving floor markings and housekeeping conditions. Redesigning Chemical storage for safe storage of chemicals as well as to ensure good handling and spillage control. Ensuring proper labeling and signage at work places. Providing rubber mats in front of electrical panels to ensure people safety. Developing new standard operating procedures. Awareness raising and motivating workers to practice energy and water saving continuously. Provide training to ensure a shift of mindset towards CP practices. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 78 4 Cleaner Production Calculation Methodology 4.1 General Overview Assessing the technical feasibility, financial viability and environmental desirability of CP options is important to identify feasible CP solutions. The selection of a CP solution for implementation requires that it should not only be techno-economically viable but also environmentally desirable. The technical evaluation determines whether a proposed Cleaner production option will work for the specific application. A CP option that is not technically feasible cannot be converted to an implementable solution. Once the option is confirmed as technically feasible, the environmental and financial viabilities are assessed. Quantification of the CP options is key to the success of the CP assessments. The expected savings for the options, both in terms of resources and the monetary, is looked at by the factories to decide upon their implementation. This chapter presents the calculations used to estimate the savings expected from the CP options. 4.2 Thermal System The boiler is main thermal utility used in textile processing. The steam generated from the boilers is used as the source of heat in the processes. Natural Gas (NG) is the energy source used in boilers. The steam generated is transferred through insulted pipelines which are equipped with steam traps for maintaining the steam quality. In some operations steam is used directly while in others it is used indirectly to achieve heat transfer. In operations where steam is used indirectly the condensate generated is expected to be recovered and reused back in the boiler as feed water. The heat content of the condensate helps in reducing the NG consumption. For the various CP opportunities related to thermal energy identified under this project, the calculation methods used for estimating the savings are given in the following sections. 4.2.1 Savings from Steam Line Insulation Insulation reduces heat loss in steam through piping and valves by repairing or adding insulation. Savings Calculations: Surface Temperature difference (0C) = Surface Temperature without Insulation (0C) - Surface Temperature with Insulation (0C) Heat Loss from uninsulated pipe (kW) = Heat loss factor at surface temperature difference (kW/m)and pipe diameter X Length of uninsulated pipe (m) Total Heat Loss Per Day (kWh) = Heat loss from uninsulated pipe 1 (kW) + . + Heat loss from uninsulated pipe n (kW) Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 79 X Number of Working Hours (h) CNG saving per day (m3) = Total Heat Loss per day(kWh) / Calorific Value of CNG (kJ/m3) Financial saving/day (BDT) = CNG Saving per day (m3) X Cost of CNG (BDT/m3) Financial saving /Annum (BDT) = Financial saving/day (BDT) X 340 days (working days per annum) 4.2.2 Savings from Condensate Line Insulation Condensate line Insulation reduces heat loss from condensate through piping by repairing or adding insulation. Savings Calculations Surface Temperature difference (0C) = Surface Temperature without Insulation (0C) - Surface Temperature with Insulation (0C) Heat Loss from uninsulated pipe (kW) = Heat loss factor at surface temperature difference (kW/m)and pipe diameter X Length of uninsulated pipe (m) Total Heat Loss Per Day(kWh) = Heat loss from uninsulated pipe 1 (kW) + . + Heat loss from uninsulated pipe n (kW) X Number of Working Hours (h) CNG saving per day (m3) = Total Heat Loss per day(kWh) / Calorific Value of CNG (kJ/m3) Financial saving/day (BDT) = CNG Saving per day (m3) X Cost of CNG (BDT/m3) Financial saving /Annum (BDT) = Financial saving/day (BDT) X 340 days (working days per annum) 4.2.3 Steam Trap Drain Points are part of the steam network which are installed for removing water in the pipes accumulated due to condensation of steam. The presence of water causes water hammering. Steam traps are provided at the drain points to avoid leakage of steam. Following table gives selection guide for steam trap installation for various applications. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 80 Application Feature Suitable trap Steam mains - Open to atmosphere, small capacity - Frequent change in pressure - Low pressure - high pressure Thermodynamic type Equipment Heat exchanger etc. - Large capacity - Variation in pressure and temperature is undesirable - Efficiency of the equipment is a problem Mechanical trap, Bucket, Inverted bucket, float Tracer line Instrumentation - Reliability with no over heating Thermodynamic & Bimetallic 4.2.4 Savings from Boiler Feed Water Tank Loss reductions The feed water tank generally receives the condensate returns form the system and therefore the water is at a high temperature. Reducing the heat losses from the feed water tank contributes in energy savings and thus reduction of CNG consumption. Savings Calculations Surface Temperature difference (0C) = Surface Temperature without Insulation (0C) - Surface Temperature with Insulation (0C) Heat Loss from uninsulated area (kW) = Heat loss factor at surface temperature difference (kW/m) and surface area X Length of uninsulated surface (m) Total Heat Loss Per Day(kWh) = Heat loss from uninsulated area 1 (kW) + . + Heat loss from uninsulated area n (kW) X Number of Working Hours (h) CNG saving per day (m3) = Total Heat Loss per day(kWh) / Calorific Value of CNG (kJ/m3) Financial saving/day (BDT) = CNG Saving per day (m3) X Cost of CNG (BDT/m3) Financial saving /Annum (BDT) = Financial saving/day (BDT) X 340 days (working days per annum) 4.2.5 Savings from Boiler Tuning Boiler tuning is the process of maximising the energy used for generating steam and reducing the heat and energy losses, thus improving the overall boiler efficiency. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 81 Economizer is a heat exchanger installed to recover heat from the flue gases. The heat exchange is mostly used to preheat the incoming water in the boiler and raise its temperature before it enters the boiler. Economizers, thus contributes to reduction of CNG consumption in the boiler and thus helps to improve its efficiency. In order to tune the boiler, the efficiency tests to estimate excess air and heat loss are carried out using instruments (by O2 or CO2 analyzer and thermocouple) and post this the required corrections made. Post the correction again the boiler efficiency is carried out to estimate the efficiency improvement in the boiler system. 4.2.6 Savings from Insulation of Hot water tank The hot water tank is used to store and provide process water to the process equipment. Reducing the heat losses from the hot water tank contributes in energy savings and thus reduction of CNG consumption. Savings Calculations Surface Temperature difference (0C) = Surface Temperature without Insulation (0C) - Surface Temperature with Insulation (0C) Heat Loss from uninsulated area (kW) = Heat loss factor at surface temperature difference (kW/m) and surface area X Length of uninsulated surface (m) Total Heat Loss Per Day(kWh) = Heat loss from uninsulated area 1 (kW) + . + Heat loss from uninsulated area n (kW) X Number of Working Hours (h) CNG saving per day (m3) = Total Heat Loss per day(kWh) / Calorific Value of CNG (kJ/m3) Financial saving/day (BDT) = CNG Saving per day (m3) X Cost of CNG (BDT/m3) Financial saving /Annum (BDT) = Financial saving/day (BDT) X 340 days (working days per annum) 4.2.6 Savings from elimination of steam leaks The figure 4-1 is nomogram to estimate the steam loss for steam at different reassures and the hoe diameter. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 82 For the steam leakage to calculated, the hole/ orifice size is noted and based the steam pressure the steam leakage is estimated from the nomogram. Steam Leakage (kg/h) identified from the nomogram (figure 4-1) Total Heat Loss Per Day(kg) = Heat loss from Hole 1 (kg/h) + . + Heat loss from Hole n (kg/h) X Number of Working Hours (h) Financial saving/day (BDT) = Steam Generation Cost (BDT) X Total Heat Loss Per Day(kg) Financial saving /Annum (BDT) = Financial saving/day (BDT) X 340 days (working days per annum) 4.3 Electrical System Electrical energy is all across the textile processing plant, from lighting to process equipments. Most of the utilities textile plant are powered by electrical energy. For the various CP opportunities related to electrical energy identified under this project, the calculation methods used for estimating the savings are given in the following sections. 4.2.1 Savings from Replacement of Magnetic Ballast and Tube lights Figure 4-1: Nomogram to estimate the steam loss Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 83 Energy Saving From Electronic Ballast (kW) = Electrical Energy Consumption with Magnetic Ballast (kW) - Electrical Energy Consumption with Electronic Ballast (kW) Total Energy Saving from Electronic Ballast (kW) = Energy Saving from Electronic Ballast (kW) X Total number of Fluorescent lamps with Magnetic Ballast Electrical Energy saving per Day (kWh) = Total Energy Saving from Electronic Ballast (kW) X Probable usage day (hours) Financial saving/day (BDT) = Daily Electrical Energy Cost (BDT/day) X 340 days (working days per annum) 4.2 Savings from Variable Frequency Drives (VFDs) or soft starters VFD controllers are used with a range of applications. In textile processing it has applications with pumps, compressors and air blowers. For the savings estimates with VFDs, the damper (in case of air handling) or valve (in case of liquid handling) are evaluated to understand the percentage opening. If the probability of rpm controlling with VFD is difficult, still it is possible to get the energy saving benefit using VFD or soft starter. The general saving calculation made is based on starting current reduction and is given as follows: Energy Saving From VFD (kW) = Electrical Energy Consumption without VFD (kW) - Expected Electrical Energy Consumption with VFD (kW) Energy Saving fromVFD (kWh) of Motor 1 per day = Energy Saving from VFD (kW) X Total number of operating Hours per day Total Energy Saving per day (kW) = Energy Saving from motor 1 (kWh) per day + . + Energy Saving from motor n (kWh) per day Financial saving/day (BDT) = Electrical Energy Cost (BDT) X Electrical Energy saving per day (kWh) Financial saving /Annum (BDT) = Financial saving/day (BDT) X 340 days (working days per annum) Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 84 As for example, In Ring shine Textile, they installed VFD across 9 motors during the follow up period and the annual saving calculation comes up as follows: Energy saving from all motors per day: (18x12x.2 + 18x12x.2 + 22x18x.2 + 22x18x.2 + 22x16x.2 22x16x.2 + 45x24x.2 + 55x24x.2) = 944.8 kWh Financial saving/day: 1.51x944.8 BDT = 1426.7 BDT (electricity cost: 1.51 BDT/kWh) Financial saving/annum: 1426.7x340 = 485060 BDT (assuming annual working days as 340) NG saving/annum: 944.8x340x0.232 m3 = 74525 m3 (SFC of generator: 0.232 m3/kWh) GHG emission reduction/annum: 74525x1.96 kg CO2e = 146070 kg = 146 ton 4.4 Pneumatic System Compressed air is a critical utility of textile processing utilized for a variety of end-uses such as pneumatic tools and equipment, instrumentation, cleaning purposes, etc. Compressed air is an expensive form of energy with losses occurring from leakages or excessive unwarranted consumption. Reduction in these losses can be achieved through various opportunities. The savings estimation from these options are discussed below. 4.4.1 Installation of Air Nozzles The air nozzles being used, the air flow rate is a requirement (for example 4 m3/min @ 5bar g) Probable air usage/day (m3)(Without Nozzles) = Approximate air volume against different orifice dia@5 barg (m3/min) X Total Time of exposure per day(min) Probable air usage/day (m3)(With Nozzles) = Probable air flow rate using nozzle (4 m3/min) X Total Time of exposure per day(min) Compressed Air saving/day(m3) = Probable air usage/day (m3)(Without Nozzles) - Probable air usage/day (m3)(With Nozzles) Financial saving/day (BDT) = Compressed Air Generation Cost (BDT) X Compressed Air saving/day(m3) Financial saving /Annum(BDT) = Financial saving/day(BDT) X 340 days (working days per annum) 4.5 Textile Process The process modifications in the textile processes results may result in either savings in chemicals and auxiliaries, water conservation or in energy conservation. For every CP option the savings expected through reduction of chemicals and auxiliaries use, amount of fresh water savings expected and the amount of energy in terms of natural gas, steam are estimated. The financial savings are calculated by using the actual cost of each of these items. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 85 4.6 Factory Provided Saving (not specified) Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 86 5 User Group Methodology & Findings This chapter has been prepared by SEBA Ltd and all correspondence regarding this chapter should be directed to SEBA Ltd. 5.1 USER GROUP METHODOLOGY & FINDINGS: WHAT: is a methodology adopted in industrial clusters to share and find solutions for problems among the members of that group OBJECTIVE: Creating a sharing and learning platform among similar kind of industries. TARGETS: Companies can learn about and work together on the feasibility of implementation of several improvement options. User group methodology is a cost effective method of consultancy. For trial issues, companies can rely on implemented ones from other companies and can go for it with much more conviction. Companies can know about local industry standards and on new technologies. ACTUAL EXECUTION & RESULTS: SEBA Limited dealt with 50 factories under Water PaCT program. For UG sessions, total 5 groups had been created and for each group, total 5 sessions had designed. As advised by IFC, TTBC (Textile Technical Business Center) which is an entity funded by IFC supported by BGMEA was the key partner in UG sessions and played the key role in execution. The basic considerations adapted for each UG Session was: Fixing five key subject closely related to CP opportunities commonly explored during assessment Informing discussion details to responsible authorities of each factories prior to the session A good time for TTBC for their B2B session where they presents available technical sources related to the discussion topic Invite factory CP team members for sharing their experiences, thoughts on discussed topic Keeping fun elements for ice breaking Supplying all presentations to participants later on Having evaluation feedback from participants for further improvements The five topics chosen for five sessions were as follows: Metering system for Textile Industries Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 87 Efficient operation of Compresses air system Process control and optimization in wet process Reuse & recovery in Wet process Steam Engineering & efficient usage Tremendous energy had been shown by the factory CP team members throughout the UG sessions and from the evaluations from the participants, it was also evident. The evaluation summary is given through following graphs considering feedbacks form all 5 sessions: 0% 4%7%24%65%0%FACILITATOR/ PRESENTERS(S) KNOWLEDGE AND SKILLSPoorSomewhat SatisfactorySatisfactoryVery satisfactoryExcellentNo comment0%0%14%27%56%3%TECHNICAL CONTENTPoorSomewhat SatisfactorySatisfactoryVery satisfactoryExcellentNo commentFinal report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 88 0% 0% 3%42%55%0%PARTICIPANTS INTERCATIONPoorSomewhat SatisfactorySatisfactoryVery satisfactoryExcellentNo comment0% 0%34%31%30%5%MATERIALS AND HANDOUTSPoorSomewhat SatisfactorySatisfactoryVery satisfactoryExcellentNo comment0% 3%14%23%60%0%OVERALL QUALITY OF THE TRAININGPoorSomewhat SatisfactorySatisfactoryVery satisfactoryExcellentNo commentFinal report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 89 0%67%33%TO WHAT EXTENT DID THIS EVENT MEET THE STATED OBJECTNot at allGoodVery much0%55%45%TO WHAT EXTENT DID THIS EVENT MEET YOURPROFESSIONAL/LEARNING NEEDSNot at allGoodVery much0% 0%14%32%54%MY KNOWLEDGE/SKILLS INCREASED AS A RESULT OF THISEVENTStrongly DisagreeNeitherSomewhat agreeAgreeStrongly AgreeFinal report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 90 0% 0%13%32%55%THE KNOWLEDGE/SKILLS GAINED THROUGH THIS EVENT AREDIRECTLY APPLICABLE TO MY JOBStrongly DisagreeNeitherSomewhat agreeAgreeStrongly Agree0% 0%12%41%47%THE DURATION OF THIS EVENT WAS ADEQUATEStrongly DisagreeNeitherSomewhat agreeAgreeStrongly Agree0% 0%38%26%36%THERE WAS SUFFICIENT TIME FOR Q & AStrongly DisagreeNeitherSomewhat agreeAgreeStrongly AgreeFinal report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 91 5.2 User Group Meeting as organized by SEBA 5.2.1 UG Meeting - 1 Agenda: Mr. Hasan Iqbal of SEBA and Tarek Amin of TTBC welcomed all the participants for joining the UG meeting. Mr. Amin introduced some suppliers of metering systems and went for the discussion session about TTBC and its functionality for helping factories to learning and achieving technological awareness and insights to improve productivity in the Textiles sector. He also explained the objectives of TTBC and emphasized on improving knowledge sharing and performance between the factories. He described Cleaner Production Management Systems (CPMS) and to focus on reuse, recycle and reduce concept for proper resource management to improve sustainability in the textile industry. Overall meeting agenda was to cover the following areas: Importance of metering system Metering system improvability Advantages & benefits of metering systems Metering system design functionality & its benefits How metering systems can improve baseline performance of the overall factory? Improvement of KPI through metering systems Identifying resource costs by the help of metering system Productivity improvement through complete metering system implementation Good practices & knowledge sharing session: Few factory practices and general ideas regarding metering systems came up from the participants. They discussed about the standard benchmarks of metering systems and how it benefited to the factory. Mr. Md. Iqbal Hossain from Abanti Color Tex Ltd. explained how metering systems improved their productivity. He stated that after implementing the metering systems in Abanti Color Tex Ltd., they can now observe the differences between consumption and generation pattern and take necessary steps to improve the productivity according to the need. Mr. Harun-ur Rashid from JM Fabrics Ltd. also expressed that they have installed water flow meters for recycling cooling water. He discussed and shared the implementing strategies and designing criteria of metering systems for water flow meters. He also shared how setting up water flow meters after deep pump and before each machine gives an idea about the exact consumption of resources. Mr. Zaber Al Ahamed from Fariha Knit Tex Ltd. expressed that by installing water flow meters against each Slavos machine improved the productivity and KPI of the overall production. Previously the KPI for dyeing was 78 litres/kg but now its around 60-65 litres/kg. Fariha Knit Tex Ltd. got significant benefits and saved a lot of water consumption just by improving metering systems in their factory. Few factory practices and general ideas regarding metering systems came up from the participants. They discussed about the standard benchmarks of metering systems and how it benefited to improve the productivity of the factory. Mr. Atiqul Isalm and Mr. Tauhidul Islam from Purbani fabrics Ltd explained how metering systems improved their productivity. They explained that after improving the metering systems in Purbani fabrics Ltd, they reduce water consumption per kg fabric production and also raising awareness among the Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 92 worker about resource management. Before the dyeing water consumption was 200 litres/kg and now it is 120 to149 litres/kg, which came just through improving metering systems. They also explained the importance of implementing metering system by analysis data and product wise KPI. Mrs. Ripon Nandi from Model de Capita also shared his view on improving metering system in the factory. He emphasized that it is the first step before going for any improvements in terms of reducing consumption of natural resources. Only having the metering system one can develop the KPIs and from there next level of target can be set. Mr. Hafizur Rahman and Mr. Rashidun Nabi expressed about their recent process modification, Central controlling system and also TDS control system. Before the dyeing water consumption was 220 liters/kg and now by doing process modification and newly install SCLAVOS machine, it is 100 to 110 liters/kg, which came just through improving metering system. Open discussion Wrap-up Comments: Mr. Kamrul Ahsan thanked them for their participation and experience sharing. He concluded with the next meeting targets which are as follows: Metering system design and strategies for implementation Figure out the balance diagrams for water, steam, power & compressed air. Importance for identifying all resource costs through metering systems 5.2.2 UG Meeting - 2 Agenda: Mr. Kamrul Ahsan started the discussion regarding the meeting agenda of UG 1.2, which is Efficient operation on compressed air system. Overall meeting agenda was to cover the following areas: Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 93 Importance on efficiency operation on compressed air system. Compressed air system standard installation. Typical compressed air system layout. Compressed air system fact sheet Types of compressor system. Saving opportunities @supply side. Saving opportunities @demand side. CP typical option Compressed air cost Compressed air system leak test procedure. Heat recovery system from compressor. Mr. Kamrul Ahsan described each point in terms of Cleaner Production perspective with interactive power point presentation slides and through group discussion among the participants. He asked the participants to share their valuable knowledge and experiences from their respective factories, so that others can get the technological ideas and knowledge to improve the overall productivity in an energy efficient way. Good practices & knowledge sharing session: Face to face experience sharing and specific query exchange Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 94 Among others, Mr. Dolan from EOS Textile also expressed how they saved water by using heat recovery from water cooled compressor. They started using vacuum cleaner to clean machine and also raise the awareness among the worker about importance of compressed Air. Wrap-up Comments: Mr. Kamrul Ahsan (SEBA Ltd.) thanked them for their participation and experience sharing. He concluded with the next meeting targets which are as follows: Metering system design and strategies for implementation Figure out the balance diagrams for water, steam, power & compressed air. Importance for identifying all resource costs through metering systems Compressed air cost analysis Compressed air layout 5.2.3 UG Meeting - 3 Agenda: Mr. A S M Tareq Amin (TTBC) started discussion regarding the meeting agenda which is Process control and optimization in wet process according to Cleaner Production perspective. Overall meeting agenda was to cover the following areas: Recap and introduction Discuss about TTBC and CP management system. Process control and optimization in wet process Super bleaching process Mr. A S M Tareq Amin described each point in terms of Cleaner Production perspective with interactive power point presentation slides and through group discussion among the participants. He said TTBC is a center of excellence, information, and action for Cleaner Production in textile industries and also go through some CP management system points given below: Omitting unnecessary steps High efficiency dyes Rinsing Conversation Enzyme Technology Substituting restricted and hazardous chemical Increase RFT Low temperature bleaching Quality control policy Proper use of laboratory equipment calibration. Developing SOP Blind dyeing Identifying control points. Good practices & knowledge sharing session: Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 95 Challenging others to learn more Mr. Biswajit Banik from Huntsman and Mr. Shahid Imam from Texco Tech delivers their speech and described each point in terms of Cleaner Production perspective with interactive power point presentation slides and through group discussion among the participants. Process control and optimization: Process optimization is a management approach and a synchronization procedure. Thus it demands and assure the involvement of top management through middle management to lower management. Enable the process related guy to think out of box and give full control on the entire value chain from selection of the yarn to fabric processing and finishing. Process Optimization bring benefits from top management to middle management in the form og business case and KFP respectively. Super Bleaching Process (UNICELL SPC Features): Sequestering, stabilizer, wetting, Washing, activator, PH collapsor all in one product to perform all the bleaching needs. Strong detergency towards fatty and oiling substances and effective dispersing behavior to keep them away from the fiber and Unicel SPC Liquid gives highest degree of bleaching performance to all discontinuous process. There some bleaching process is given below: 1. Standard Atmospheric Bleaching Process. 2. Atmospheric Bleaching Process with UNICEL SPC. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 96 3. Standard HT Bleaching Process 4. HT Process with UNICEL SPC 5.2.4 UG Meeting - 4 Agenda: Opening B2B Session driven by TTBC highlighting TTBC role and future activities Discussion on Salt Recovery Plant Group discussion on Reuse, Recovery among participant from factory. GroupWise presentation about reuse, recovery Salt Recovery Plant: Presented by Aqua Tech Textile industries are one of the largest water users which are also polluting the rivers and surface water by discharging that water. A few textile industries have taken some initiatives to reduce water consumption and some others have functional Effluent Treatment Plant (ETP) before discharging to the environment. Group presentation by participants After initial study, it is clear that Total Dissolved Solid (TDS) is the main problem which is sometimes forcing the effluent managers to dilute the effluent to bring the ETP discharge within the norms of Department of Environment (DoE) in terms of TDS. This TDS is mainly caused from the used Glauber salt / Common Salt in the dyeing operation. A Salt Recovery Plant (SRP) is the possible solution. This will eliminate the problem of TDS and also help to recover used salt up to a considerable amount. Selection of proper technology and effective setting of that technology requires expert support. Other residue chemicals in the effluent should be controlled analyzed for designing and implementing a zero discharge factory. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 97 1. ETP performance will improve up to 40 percent. 2. ETP Operation cost will reduce significantly. 3. ETP Sludge will be reducing by using SRP. 4. More Environ friendly Sludge will produce from ETP. 5. 55% fresh water will be back from SRP_RO Unit for Process water use. 6. Organic Load of ETP reduce up to 60 percent. 7. Outlet TDS of ETP should be in control by using SRP etc. 8. Water Recycle Option enhance significantly. Extra benefit from Salt Recover Plant (SRP): Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 98 5.2.5 UG Meeting - 5 Agenda: Steam Engineering: Boiler Efficiency: Following discussions were made by industry experts We expect that boiler will always continue to generate at the rated efficiency. The truth is that one of the most critical parameters in boiler operation is its delivery efficiency in actual operation. Scouring & Bleaching Neutralization Hot wash Neutralization Rinsing Dye Bath Soaping Finishing & Packing Softener Fixation Dye Bath collection Colourremove RO Filtration High TDS Saline Fresh Water for Reuse Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 99 We say boiler efficiency is the most critical parameter because every boiler generates steam (we have not come across a boiler that does not generate steam.) What distinguishes one boiler from another is actually at what cost steam is generated. True delivered boiler efficiency to be lower by 3 % to 12% than rated and yes, all these plants through they were getting the rated efficiency or may be just slightly lower. Condensate and Flash steam recovery general practice in factories: Huge gap between quantum of condensate being recovered and potential for recovery observed across all plants. Across many plants, boiler feed water temperature ambient and condensate is being drained. In plants where condensate is recovered, it is doing using an electrical pump leading to loss of useful heat. Flash steam is normally not recovered and is vented. Flash steam can be recovered and used for feed water heating. Multiple benefits of condensate recovery: Condensate water contains 20% energy of steam. Returning condensate improves the feed water temperature and thus lowers fuel bill. Returning condensate to feed water tank cuts the makeup water requirements. The condensate returned dose not needs to undergo water treatment and this saving treatment cost. It has no TDS. It reduces the requirement of blow down thereby curtailing blow down losses. Reduce the cost for oxygen scavenging chemicals, since the improved temperature will reduce the amount of dissolve oxygen almost 75%. Factors should be considered before installing Economizer in existing boiler: Usually a boiler with a pressurized economizer increases the efficiency of the boiler. There are some issues which we have to think about before taking decision of buying & putting an economizer. Burner Boiler Performance Single Element drums level control system Feed Pump Modification job Waste Heat Recovery Boiler (WHRB): One supplier discussed about WHRB and their working principle. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 100 Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 101 Chapter 06: Conclusion 6.1 Constraints Prior to the actual assessment a low awareness of management was the main constraint. This is caused by the priority setting which is mostly dominated by production issues and by underestimating the costs for water, energy and material losses. The initial assessment, or the questionnaire, and one-on-one talks by the local coordinator did raise the awareness to the level that when starting the assessment the relevant staff and management was present and aware and a limited amount of data was available. Also most factories had at that stage already established a basic CP team. Another result of the intensive preparation was that the local and international team were allowed to go everywhere in the factory premises and allowed to talk to everybody. Generally the atmosphere in which the first visits took place was considered to be pleasant and open. 6.1.1 Project Timelines Although factory staff and management were on the whole interested and committed to the CP project the implementation of assessment and later on the options did hamper from internal and external causes. The political turmoil caused delays in activities led by the international team such as walkthroughs and debriefings. Creative solutions such as using Skype and visiting headquarters instead of factories during the debriefings were approved by IFC and in the end the political situation caused minor delays. In the monitoring phase the delays in implementation are caused by priority setting which in most cases are dominated by production issues, and in a few cases by financial constraints, renovations, change in CP team and management. On the other hand it should be noted that it is not common for a SME to implement a medium cost options such as boiler heat recovery within 6 months. For these major options the monitoring period is simply too short. 6.1.2 Availability of baseline data In most of the cases, availability of baseline data was a challenge. The main reason was the lacking of proper metering system and even metering systems are available, in some cases, data logging wasnt consistent. On the other hand, there were some exceptional factories where data logging were present in most areas and even some sort of analysis was seen which is encouraging. Due to unavailability of baseline data, the working team had to spend time for collection of data (where meters were available) or had to adapt indirect calculation method based on physical checking at site. 6.1.3 Resource monitoring & measurement In general, at the beginning of the project, it was observed that awareness among factory managements on resource monitoring and measurement was not enough to understand the benefit of measurement. If we categorize the status of 50 factories on preparedness, most were at primary level whereas some exceptions were also available. Somehow, this issue is not in the top priority list of managements and activities like CP assessment can be a good driver to shake them and make understood on the necessity of resource monitoring. Awareness sessions along with the display of positive case studies among owners as well as operations people can make the campaign more successful. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 102 6.1.4 Focus on production In general, the team found the focus on production as a top priority issue and sometimes it a challenge to get factory people engaged in CP assessment works. Still, focus on production is the main highlight for any production unit. Consequently, resource management and even proper maintenance of equipment are mostly compromised. The initial pressure comes from the top management and thats why, top management can play a big role for changing the mindset and move forward for a productive operation where the benefits of resource management can be highlighted and people should be encouraged to come forward on exploring saving opportunities. 6.2 Achievements & Success Due to the continuous attention of the local service provider and detailed support by the local team in each and every CP assessment the 50 CP assessment can be considered an achievement. Drop out of companies were minimal and certainly much lower than what can be commonly expected in voluntary CP programs (>10%). The strenuous selection procedure as executed by IFC is largely responsible for this success. Off course all involved organizations played their respective part in the project and are responsible for its success. Also after the assessment period the majority of companies show a good commitment to the CP approach and have started to implement a significant number of options. Apart from a few exceptions it can be in general agreed that the project has been successful in initiating improvement programs in a significant number of companies. Especially when considering the diversity in size, process, product and management maturity and age. The teams have overcome most barriers when regarding data collecting, option generation and implementation. 6.3 Lessons learnt The initial access is always a challenge to convince the factory team and ensure support and participation from them. The best approach is to earn the mandate from top management and maintain a good peer relationship with factory CP team. Proper interpretation of project highlights and expectations plays also a good role in maintaining a good relationship. Comparing available data with realistic benchmark figures play an important role to convince management and these available data need to be verified in order to make sure that the represent the actual situation. The user Group meeting plays a good and effective role on enhancing the understanding of CP among the audiences. The cross factory team communication can unfold lots of new thoughts and spread the real benefits of implementation among the operation people. Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521 103 Annexes are available at IFC Bangladesh and are upon request Annex: pre-assessment questionnaire Annex: checklist (Utility, process, ETP, WASH, OHS&EMS) Annex: Action Plan