103
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 basic CP IVAM

Embed Size (px)

Citation preview

Page 1: Final report basic CP IVAM

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

Page 2: Final report basic CP IVAM

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 sector’s 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.

Page 3: Final report basic CP IVAM

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 Consultant’s 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

Page 4: Final report basic CP IVAM

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

Page 5: Final report basic CP IVAM

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

Page 6: Final report basic CP IVAM

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.

Page 7: Final report basic CP IVAM

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 wasn’t

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.

Page 8: Final report basic CP IVAM

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.

Page 9: Final report basic CP IVAM

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.

Page 10: Final report basic CP IVAM

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 hasn’t 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

Page 11: Final report basic CP IVAM

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

Page 12: Final report basic CP IVAM

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

Page 13: Final report basic CP IVAM

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

Page 14: Final report basic CP IVAM

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.

Page 15: Final report basic CP IVAM

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).

Page 16: Final report basic CP IVAM

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

Page 17: Final report basic CP IVAM

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

Page 18: Final report basic CP IVAM

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 SME’s 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

Page 19: Final report basic CP IVAM

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 company’s 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, SOP’s 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

Page 20: Final report basic CP IVAM

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.

Page 21: Final report basic CP IVAM

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.

Page 22: Final report basic CP IVAM

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 ETP’s 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 KPI’s 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 consultant’s 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 Consultant’s 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.

Page 23: Final report basic CP IVAM

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.

Page 24: Final report basic CP IVAM

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

Page 25: Final report basic CP IVAM

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

Page 26: Final report basic CP IVAM

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

KPI’s

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.)

Page 27: Final report basic CP IVAM

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

KPI’s

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

Page 28: Final report basic CP IVAM

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

KPI’s

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

Page 29: Final report basic CP IVAM

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

KPI’s

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

Page 30: Final report basic CP IVAM

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

KPI’s

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

Page 31: Final report basic CP IVAM

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

KPI’s

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

Page 32: Final report basic CP IVAM

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

KPI’s

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

Page 33: Final report basic CP IVAM

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

KPI’s

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

Page 34: Final report basic CP IVAM

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

KPI’s

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.)

Page 35: Final report basic CP IVAM

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

KPI’s

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.)

Page 36: Final report basic CP IVAM

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

KPI’s

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

Page 37: Final report basic CP IVAM

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

KPI’s

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

Page 38: Final report basic CP IVAM

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

KPI’s

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

Page 39: Final report basic CP IVAM

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

KPI’s

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

Page 40: Final report basic CP IVAM

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

KPI’s

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

Page 41: Final report basic CP IVAM

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

KPI’s

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

Page 42: Final report basic CP IVAM

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

KPI’s

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

Page 43: Final report basic CP IVAM

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

KPI’s

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

Page 44: Final report basic CP IVAM

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

KPI’s

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

Page 45: Final report basic CP IVAM

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

KPI’s

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

Page 46: Final report basic CP IVAM

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

KPI’s

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

Page 47: Final report basic CP IVAM

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

KPI’s

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)

Page 48: Final report basic CP IVAM

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

KPI’s

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

Page 49: Final report basic CP IVAM

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

KPI’s

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

Page 50: Final report basic CP IVAM

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

KPI’s

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

Page 51: Final report basic CP IVAM

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

KPI’s

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

Page 52: Final report basic CP IVAM

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

KPI’s

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.)

Page 53: Final report basic CP IVAM

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

KPI’s

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

Page 54: Final report basic CP IVAM

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

KPI’s

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

Page 55: Final report basic CP IVAM

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

KPI’s

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

Page 56: Final report basic CP IVAM

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

KPI’s

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

Page 57: Final report basic CP IVAM

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

KPI’s

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

Page 58: Final report basic CP IVAM

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

KPI’s

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)

Page 59: Final report basic CP IVAM

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

KPI’s

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

Page 60: Final report basic CP IVAM

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

KPI’s

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.

Page 61: Final report basic CP IVAM

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

KPI’s

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.

Page 62: Final report basic CP IVAM

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

KPI’s

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.

Page 63: Final report basic CP IVAM

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

KPI’s

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.

Page 64: Final report basic CP IVAM

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

KPI’s

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.

Page 65: Final report basic CP IVAM

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

KPI’s

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.

Page 66: Final report basic CP IVAM

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

KPI’s

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.

Page 67: Final report basic CP IVAM

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

KPI’s

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.

Page 68: Final report basic CP IVAM

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

KPI’s

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.

Page 69: Final report basic CP IVAM

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

KPI’s

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.

Page 70: Final report basic CP IVAM

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

KPI’s

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.

Page 71: Final report basic CP IVAM

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

KPI’s

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.

Page 72: Final report basic CP IVAM

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

KPI’s

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.

Page 73: Final report basic CP IVAM

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

KPI’s

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.

Page 74: Final report basic CP IVAM

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

KPI’s

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.

Page 75: Final report basic CP IVAM

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

KPI’s

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.

Page 76: Final report basic CP IVAM

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.

Page 77: Final report basic CP IVAM

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.

Page 78: Final report basic CP IVAM

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)

Page 79: Final report basic CP IVAM

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.

Page 80: Final report basic CP IVAM

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.

Page 81: Final report basic CP IVAM

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.

Page 82: Final report basic CP IVAM

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

Page 83: Final report basic CP IVAM

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)

Page 84: Final report basic CP IVAM

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.

Page 85: Final report basic CP IVAM

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)

Page 86: Final report basic CP IVAM

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

Page 87: Final report basic CP IVAM

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 SKILLS

Poor

Somewhat Satisfactory

Satisfactory

Very satisfactory

Excellent

No comment

0%0%

14%

27%56%

3%

TECHNICAL CONTENT

Poor

Somewhat Satisfactory

Satisfactory

Very satisfactory

Excellent

No comment

Page 88: Final report basic CP IVAM

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

88

0% 0% 3%

42%

55%

0%

PARTICIPANTS INTERCATION

Poor

Somewhat Satisfactory

Satisfactory

Very satisfactory

Excellent

No comment

0% 0%

34%

31%

30%

5%

MATERIALS AND HANDOUTS

Poor

Somewhat Satisfactory

Satisfactory

Very satisfactory

Excellent

No comment

0% 3%

14%

23%60%

0%

OVERALL QUALITY OF THE TRAINING

Poor

Somewhat Satisfactory

Satisfactory

Very satisfactory

Excellent

No comment

Page 89: Final report basic CP IVAM

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

89

0%

67%

33%

TO WHAT EXTENT DID THIS EVENT MEET THE STATED OBJECT

Not at all

Good

Very much

0%

55%

45%

TO WHAT EXTENT DID THIS EVENT MEET YOUR

PROFESSIONAL/LEARNING NEEDS

Not at all

Good

Very much

0% 0%

14%

32%54%

MY KNOWLEDGE/SKILLS INCREASED AS A RESULT OF THIS

EVENT

Strongly Disagree

Neither

Somewhat agree

Agree

Strongly Agree

Page 90: Final report basic CP IVAM

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

90

0% 0%

13%

32%55%

THE KNOWLEDGE/SKILLS GAINED THROUGH THIS EVENT ARE

DIRECTLY APPLICABLE TO MY JOB

Strongly Disagree

Neither

Somewhat agree

Agree

Strongly Agree

0% 0%

12%

41%

47%

THE DURATION OF THIS EVENT WAS ADEQUATE

Strongly Disagree

Neither

Somewhat agree

Agree

Strongly Agree

0% 0%

38%

26%

36%

THERE WAS SUFFICIENT TIME FOR Q & A

Strongly Disagree

Neither

Somewhat agree

Agree

Strongly Agree

Page 91: Final report basic CP IVAM

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

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 it’s 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

Page 92: Final report basic CP IVAM

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:

Page 93: Final report basic CP IVAM

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

Page 94: Final report basic CP IVAM

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:

Page 95: Final report basic CP IVAM

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.

Page 96: Final report basic CP IVAM

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.

Page 97: Final report basic CP IVAM

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):

Page 98: Final report basic CP IVAM

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

Page 99: Final report basic CP IVAM

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.

Page 100: Final report basic CP IVAM

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

Page 101: Final report basic CP IVAM

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 wasn’t

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.

Page 102: Final report basic CP IVAM

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 that’s 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.

Page 103: Final report basic CP IVAM

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