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Bangladesh Water PaCT: Partnership for Cleaner Textile
Final Report on 50 Basic Cleaner Production
Assessments (Step 2) in the PaCT
Prepared for IFC Bangladesh
IVAM UvA BV, Amsterdam, The Netherlands
SEBA Limited, Banani, Dhaka
Amsterdam January 26, 2016
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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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.
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
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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
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
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6 Conclusion ............................................................................................................................... 101
6.1 Constraints ...................................................................................................................................... 101
6.2 Achievements & Success ................................................................................................................. 102
6.3 Lessons learnt ................................................................................................................................. 102
Annexes (upon request) 1. Pre-assessment questionnaire 2. Checklist (Utility, process, ETP, WASH, OHS&EMS) 3. Action Plan
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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Executive Summary
In 2014 and 2015 IVAM UvA BV and SEBA Ltd assessed 50 wet textile processing in Bangladesh based on
the CP methodology. This report describes the results of those 50 basic CP assessments including a 6
month monitoring phase in which the implementation of the identified options were monitored. In this
type of assessment the obvious options are identified and their benefits calculated. Obvious options
concern the (almost) visually present signs of waste and leakages whose volumes and costs are
underestimated. Obvious options are mostly in the order of improved control of parameters, improved
maintenance, improved handling of resources, recycling and reusing. Obvious options hardly require
thorough analysis and lengthy measuring periods to prove their economic and environmental feasibility.
Implementation is overall speaking also relatively easy.
Most commonly observed options are:
Recommendation Option and example investment USD
Economic benefits, USD/year
Payback time, year
Process modification
At Noman Terry Towels Ltd an analysis of acrylic cotton yarn dyeing, showed that one wash step can be dropped.
0 50,065 Instant
Water trigger nozzle Noman Terry Towel Ltd installed 10 water trigger nozzles.
58 733 0.1
Cooling water recovery Envoy Textiles Ltd recovered cooling water from gas singeing machines
7,802 2,488 3
Waste heat recovery boiler (WHRB)
Modele De Capital Industries Ltd installed a WHRB of 2 ton/h
206,245 52,399 4
Condensate recovery Ring shine Textiles Ltd recovers the condensate from Hank dyeing & spray Dyeing section
154 60,786 Instant
Insulation of hot surfaces
Noman Terry Towel Ltd insulated 2 feed tanks, 12 valves and 48 sq. feet steam lines.
2,167 1,436 1.5
Air trigger nozzle Esquire Knit Composite Limited 60 no's installed 6 air trigger nozzles.
140 15,408 Instant
Variable Frequency Drives
Mondol Knit Composite installed 6 VFDs.
11,000 3,866 2.8
Installing energy efficient LED light
Paramount Textile installed 3200 LED light (22 watt)
24,410 6,936 3.5
Improving metering system
Textown Ltd installed 6 water flow meters
13,271 0 0
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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Financial implications In the 50 CP company assessments 545 options were recommended which may incur an estimated total investment of 5,626,789 USD with which an total potential benefit of 3,605,020 USD can be obtained. The estimated payback is on average nineteen months. After a six month monitoring period it was concluded that 185 options (34% of the suggested/agreed recommendations) have been implemented with a total investment value of 1,592,909 USD and generating economic benefits of 768,020 USD per year. Simple payback of the investment is 2 years. Resource saving and Environmental benefits Within the monitoring period 185 options out of 545 identified options have been implemented by the 50 companies which have generated the following resource savings and environmental benefits. Water consumption The 50 companies managed to reduce their water consumption with 1.97 million m3 which is over 5% of the original annual consumption of 38 million m3. Of the 1.97 million m3 reduction 1.59 million m3 was obtained in the wet textile processing units. Natural gas The 50 companies managed to reduce their natural gas (NG) consumption with 10.3 million m3
which is approximately 3% of the original annual consumption 404 million m3. The corresponding financial value of the NG saving is 645,109 USD Electricity The 50 companies managed to reduce their electricity consumption with 10,389 MWh which is approximately 2% of the original annual consumption 288,284 MWh. Saving resource is equivalent to 1.64 million USD per year. Steam The 50 companies managed to reduce their steam consumption with 34,389 ton which is approximately 1.3% of the original annual consumption 2,617,187 ton. Greenhouse gases The 50 companies managed to reduce their greenhouse gases generation with 20,946 ton which is approximately 3% of the original annual generation of 794,078 ton. Wastewater The 50 companies managed to reduced their wastewater generation with 1.59 million m3 which is approximately 5% of the original annual generation of 28.9 million m3.
Implementation of policies and procedures
Most companies have implemented all proposed policies and procedures regarding chemical inventory,
occupational health and safety (OHS), water availability, safety and hygiene (WASH) and environmental
management systems (EMS). In the 50 companies the policies recommended and implemented are as
follows.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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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.
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
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During the implementation phase the situation regarding the metering did improve somewhat however
still many meters are necessary to improve the resource management in the 50 factories.
Meters installed (based on 50 CP
assessments)
Before (During
Assessment)
After (During
Follow-up visit)
% of flow meter
increased
Water flow meter 244 293 20
Electricity meters 114 123 8
NG meters 89 89 0
Steam flow meters 12 19 58
Achievements & Success
Due to the continuous attention of the local service provider and detailed support by the local team in
each and every CP assessment the 50 CP assessment can be considered an achievement. Drop out of
companies were minimal and certainly much lower than what can be commonly expected in voluntary
CP programs (>10%). The strenuous selection procedure as executed by IFC is largely responsible for this
success. Off course all involved organizations played their respective part in the project and are
responsible for its success.
Also after the assessment period the majority of companies show a good commitment to the CP
approach and have started to implement a significant number of options. Apart from a few exceptions it
can be in general agreed that the project has been successful in initiating improvement programs in a
significant number of companies. Especially when considering the diversity in size, process, product and
management maturity and age. The teams have overcome most barriers when regarding data collecting,
option generation and implementation.
Lessons learnt
The initial access is always a challenge to convince the factory team and ensure support and
participation from them. The best approach is to earn the mandate from top management and
maintain a good peer relationship with factory CP team. Proper interpretation of project
highlights and expectations plays also a good role in maintaining a good relationship.
Comparing available data with realistic benchmark figures play an important role to convince
management and these available data need to be verified in order to make sure that the
represent the actual situation.
The user Group meeting plays a good and effective role on enhancing the understanding of CP
among the audiences. The cross factory team communication can unfold lots of new thoughts
and spread the real benefits of implementation among the operation people.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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1 Introduction
1.1 Overview of Textile Sector in Bangladesh The textile industry in Bangladesh is responsible for 80% of the export earnings. It is a 18 billion USD industry and contributes approximately 30% to the Bangladesh industrial sector GDP. The sector employs 3.6 million people of whom 85% are women.
1.1.1 Environmental Issues of Textile Sector
There are approximately 1,700 washing dyeing and finishing units whose effluents impact the lives of 12+ million Dhaka residents. The groundwater depletion by industry causes the water tables to decline with 1 to 2 meters/year which leads seasonal water shortages.
1.1.2 Energy Issues of Textile Sector
Most wet textile processing industries convert the natural gas to electricity and steam using generators and boilers. The electricity is mainly used for generating compressed air and operating pumps, engines, ventilators, lighting, etc. whereas the steam is used for heating the processes baths and for drying operations. Due to the instability of the natural gas grid many factories have diesel generators on standby.
1.1.3 Wastewater disposal issue
After the tannery industry section the textile sector is the biggest polluter which significantly impacts the surface water and groundwater quality. The sector consumes 1,500 billion liters of groundwater per year for the production of 5 million tons of fabric (300 liter per kg fabric on average)
1.1.4 Occupational Health and Safety
Since the Rana Plaza and Tazreen disasters the attention for the safety in the textile has ramped up and many factories have joined initiatives like ACCORD and Alliance to improve their OHS situation.
1.2 Response to Textile Issues in Bangladesh Cleaner production is a way to improve the sustainability of the textile industry by improving the management and reducing resource consumption. Other initiatives to improve sustainability are based on occupational health and safety (OHS or OHSAS18000), environmental management systems (EMS or ISO14000), water availability safety and hygiene (WASH). The Detox campaign by Greenpeace and the ZDHC (zero discharge hazardous chemicals) initiative showed that the textile industry uses chemicals which are toxic to humans and/or endangering the environment. Brands are now engaging textile industry to avoid this kind of chemicals.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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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
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
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Mahesh Sharma
EMC
Textile engineer Developing textile engineering training module
Training textile engineering
Company visits and debriefing
Helpdesk regarding textile engineering
Dinesh Kamath
EMC
Electrical engineer/ energy
auditor
Developing electrical engineering training module
Training electrical engineering in textile industry
Factory visits (training group (6)
Helpdesk regarding electrical engineering
Loshan
Palayangoda
ISB
Mechanical engineer Developing mechanical engineering training
module
Training mechanical engineering in textile industry
Factory visits and debriefing
Helpdesk regarding mechanical engineering
Chanaka
Mahawatta
ISB
Chemical engineer Developing chemical engineering training module
Training chemical engineering in textile industry
Factory visits (training group (6)
Helpdesk regarding chemical engineering
SEBA Ltd team:
Name Role Assignment in the project
Hasan Iqbal
Team Leader
Team building
Communication with stakeholders
Planning
Logistic support
Report review
Kamrul Ahsan
Dewanjee
Deputy Team Leader Team management and delegation of authorities
Data analysis
Communication with IVAM technical team
Assessment report drafting
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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Supporting monitoring activities
Md. Habibul Islam
Senior Consultant (textile) Leading the local wet process team
Extending support in trial and option verification
Communication with factory CP team
A.K.M Alauddin
Team Leader (monitoring) Communications with factory for monitoring
planning
Ensure monitoring visits and having validation
documents
Ensure updating of monitoring documents
Abdullah Ash
Shakir
Project Engineer (electrical) Assist the wet process team
Ensure all calculations of wet process options
Co-ordinate with team leader for verifications
Maintain all related documents
Abu Bin Jubaer
Project Engineer (textile) Assist the wet process team
Ensure all calculations of wet process options
Co-ordinate with team leader for verifications
Maintain all related documents
Aurangazeb
Project Engineer
(mechanical)
Assist the CP assessment team
Ensure all calculations of boiler/steam related
options
Co-ordinate with team leader for verifications
Maintain all related documents
Faisal Rahman Project Engineer (electrical) Assist the CP assessment team
Ensure all calculations of water/electrical related
options
Co-ordinate with team leader for verifications
Maintain all related documents
Mahfujul Alim
Project Engineer (electrical) Assist the CP assessment team
Ensure all calculations of water/electrical related
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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options
Co-ordinate with team leader for verifications
Maintain all related documents
Sadnam Saniat
Hasan Risat
Project Engineer (electrical) Assist the CP assessment team
Ensure all calculations of electrical related options
Co-ordinate with team leader for verifications
Maintain all related documents
Support in draft report writing
Sharmin Akter Project Engineer (electrical) Ensure support for OHS/EMS/WASH/Chemical
management assessment
Co-ordinate with team leader for verifications
Maintain all related documents
Maintain overall data banks
1.6 Objective of Final Report
The objective of the final report is to describe the results obtained with respect to the financial
implications in terms of investment and economic benefits, resources saved and environmental impacts
reduced. The major topics to report on are: - Summary of major conclusions and recommendations
- Assumptions and calculation methodology used to estimate savings
- Number of recommendations implemented
- Total amount invested by the factories
- Cumulate savings by the factories due to savings from water, energy and GHG emissions
avoided
- Estimated water savings in liters and associated cost savings
- Estimated energy savings and associated savings
- Estimated GHG emissions avoided
- Estimated number of policies, procedures, etc. that were eliminated/improved at each of the
factories
- Estimated percentage reduction in total operational cost at each of the participating factories
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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2 PaCT Cleaner Production Assessment Methodology
2.1 Overview of Textile Processing The textile industry is among the largest industries of the world with regard to production and labor. It exhibits a typical variation in scale: from large scale mechanized to small scale traditional units. Broadly this industry is classified into the cotton, woolen en synthetic fibers industries. Wet textile processing is performed in a multistage operations which contain the following steps:
2.1.1 Sizing
In sizing the warp threads are coated with size (either starch or synthetic) to facilitate weaving by giving the threads tensile strength and smoothness. The component is then dread on the threads and remains a part of the cloth until it is removed in the subsequent processes. Generally the sizing step is not considered to be part of the wet textile processing but part of spinning and weaving.
2.1.2 Desizing
The purpose of desizing is to remove sizing ingredients , mainly starches, gums, PVA etc. The gums and PVA are removed by a simple hot wash but starch has to be degraded first into small molecules. These molecules being soluble in water are then removed through a hot wash . The desizing project is important because the presence of starch on the fabric hampers the penetration op other chemicals in the subsequent processes.
2.1.3 Scouring
Cotton being a natural fiber contains about 2 to 3% of different impurities such as waxes, fatty acids, proteins, pectin, and mineral matter. Scouring removes natural impurities other than coloring matter, particular from cotton fibers, This process is performed under highly alkaline conditions at temperatures conventionally above 1000C.
2.1.4 Bleaching
Bleaching is basically the process to destroy the natural coloring matters present in the cotton. Three typical processes are available for bleaching: sodium chlorite, sodium hypochlorite and hydrogen peroxide bleaching.
2.1.5 Mercerizing
The mercerization process is basically an alkali (NaOH) treatment given to cotton yarn or fabric so that the cotton fibers swell and attain a round-like structure from the original convoluted form. The axial ration of the cross section is reduced due to rounding. When performed under tension for 40 to 50 seconds with caustic soda this process improves luster, strength and dye uptake.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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2.1.6 Dyeing
Dyeing is a process or combination of processes which is performed to give a reasonable permanent coloration to the textile fabric. The dyeing should offer a reasonable fastness to: household washing and laundering, light, rubbing, oxidation and sublimation, perspiration. 2.1.6.1 Dyestuffs All classes of dyestuffs are chemically different and applicable for different fibers with different application methods. The most common are:
Vat dyes: insoluble dyes are made soluble using a reducing agent (sodium hydrosulphate) and oxidized and made insoluble again when attached to the cellulosic fibers
Azoic dyes: the colors are formed in the fiber by the combination of two components
Reactive dyes: the dyes react chemically in the presence of alkali with the hydroxide group of cellulose which form the linkage between the two.
Pigments: are not dyes in the true sense as they do not form chemical bonds but are held on the fiber mechanically
Acid dyes: find their main application on wool, silk, polyamide, modified acrylic and regenerated protein fibers. They are applied by a dye liquor containing, sulphuric, formic, or acetic acid or ammonium sulphate.
Disperse dyes are applied to polyamide and polyester fibers. They are colored organic substances with very low solubility in water which, during the course of dyeing are transferred from dispersion via monomolecular solution to the fiber.
2.1.6.2 Additives and other chemicals Apart from the chemicals and dyestuffs already mentioned the wet textile processing relies on a large variety of chemicals which support the processes or determine the characteristics of the final products such as salts (common salt, Glauber salt, soda ash), detergents, softeners, sequestrants, and so on.
2.1.7 Water
There are several water use categories such as processing, potable purposes, utility and laboratory use. Each requires different water quality parameters. Process uses (preparation, dyeing, and finishing) include making concentrated bulk chemical stock solutions, treat solutions (bleaching, dye bath and finish mix) and numerous washes, hot and cold. Potable water is for drinking and cooking, Utilities use includes non-contact such as cooling water, boiler water, humidifier systems, equipment cleaning etc. The source of the water is important to consider as potable water is usually chlorinated which can have an effect on the shade or cause other problems in processing. Hardness also causes problems in boiler operations (scaling) or in humidifiers (blocking).
2.1.8 Energy
Energy is mostly used in two forms, electrical to drive motors and engines, and thermal to heat process baths, calenders, singeing, etc. Sources of electricity are the national grid or generated by the company itself using diesel, coal and/or natural gas fueled generators. Thermal heat is usually provided in the form of steam, hot water or oil (in a closed system).
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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2.2 Cleaner Production Assessment Methodology The Cleaner Production assessment methodology is the most generally accepted methodology to reduce
environmental impacts in a technical and economical manner. Cleaner Production as promoted by
UNEP/UNIDO can be defined as follows:
“Cleaner Production holistic approach is a preventive, integrated strategy that is applied to the
entire production cycle to:
Increase productivity by ensuring a more efficient use of raw materials, energy and water;
Promote better environmental performance through reduction at source of waste and
emissions;
Reduce the environmental impact of products throughout their life cycle by the design of
environmentally friendly but cost-effective products. ”
Most crucial is that Cleaner Production is preferred over relying on end-of-pipe pollution controls, and
has to be regarded higher in hierarchy; going beyond pollution prevention and reducing quantities of
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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waste and eliminate part of the pollutants. Especially important is that Cleaner Production encompasses
production processes and management procedures thereby entailing less use of resources than
conventional technologies and also generates less waste and smaller amounts of toxic or other harmful
substances. It emphasizes the human and organizational dimensions of environmental management,
including good plant operation to avoid deliberate or accidental discharges.
At the same time cleaner production is not claiming to cope with all environmental problems and still
some treatment and disposal of remaining wastes will be required. Appropriate treatment systems must
be designed and installed to achieve acceptable emissions levels. However, when starting with
appropriately implementing preventive, process-integrated (Cleaner Production) measures, most likely
the scale of operation for the treatment and disposal of remaining wastes can be (much) smaller, and
thereby decreasing related investment and operating costs.
The CP-assessments shall focus on the major inefficiencies in the process to contribute to improved
performance of the companies (and thereby strengthening its competitiveness) and decreasing
environmental impact (higher consumption efficiency (raw materials, water and energy and lower
emissions) without decreasing the quality (specifications) of its products and potential intangible
benefits (positive effects on occupational, health and safety conditions).
The CP-assessments methodology is
generic and can be applied in each
type of enterprise, irrelevant which
kind of industrial sector or even
services (like tourism, hotels,
hospitals, buildings, offices) and also
irrelevant for the country. The
methodology is standard, oriented
around the 3 basic questions (where
(input/output data) – why (cause
analysis) – how (option generation)),
but logically the actual issues to
cope with during material balancing,
cause analysis and the potential
improvement areas will be sector
specific and have to be even tailored
to the specific conditions of the
client (its specific products, the
organizational structure, the culture,
the local institutional and regulatory setting, etc.).
Figure 1: cleaner production techniques
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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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
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
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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
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
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factory staff visited all relevant workshops, storages and other supporting activities. The general approach is that after the initial discussion with the management the team is split into two groups in which one group focuses on the textile processing and the other on the utilities. During the walkthrough specific questions are raised which in principle should clarify the level of (resource) management and feasibility of possible options. These options are considered to be obvious for the teams and factory staff and concern improvements in the field of standard operating practices, maintenance, recycling and reusing, equipment modification. After visiting the production site a more detailed discussion has taken place and the action plan has been established. In the action plan most relevant improvement options have been listed which need further data collection and analysis. Apart from the cleaner production related issues also other issues were assessed such as OHS (occupational health and safety), WASH (water availability, safety and hygiene), EMS (environmental management system) and the chemical inventory regarding banned chemicals took place.
2.4 Collection of Data & Analysis General data needs to be collected to develop the baseline performance (or KPI) of the resource consumption such as for water liter/kg textile processed, electricity kWH/kg, steam in kg/kg, and so on. This baseline performance (or KPI) is used to quantify the overall improvement of the resource efficiency. In the case industry indicators are available these are used to compare with the factory indicators in order to stress the importance of and illustrate the feasibility of improving. Specific data is collected which should contribute to the calculation of the performance of an activity which has been identified during the walkthrough. For example is lacking insulation of the steam pipe is observed the temperature at the surface should be measured, the diameter of the pipe, the length etc. From experience the optimal surface temperature of an insulated pipe can then be used to calculate the potential heat saving and cost. Eliminating a wash in a dyeing process saves the volume of the bath and for recycling condensate is the volume and the temperature is relevant. See chapter 4 for further requirements of data collection and measurements. The local service providers have the most relevant mobile measuring equipment to measure temperature, humidity, electricity etc. In case when these equipment is insufficient and factory meters are lacking data has to be generated using equipment characteristics such as pump volumes and operation time for example to establish the total water pumped from the deep wells. For the analysis of the causes of waste in principle the team investigates whether the level of staff can be improved, equipment can be modified, waste streams can be reused, parameters better controlled. Based on this analysis options are generated.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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2.5 General Issues Identified
2.5.1 Commitment
Overall speaking and when talking about the assessment the commitment was good. In few cases the assessment took more time as management was reluctant in allowing measurements to take place and data shared. In the end the results of most assessments can be considered good. In the 6 months implementation period most companies implemented the majority of options as identified for CP, WASH, EMS and OHS.
2.5.2 Metering
Resources and especially water are in general not metered. In case metering takes place the data is not collected or analyzed (as in related to production output). Meters in the factory do not appear to be calibrated on a regular basis. As a consequence most meters appear neglected and un-serviced except for the meters on the wastewater treatment facilities.
2.5.3 Access to the factory and or facilities
During the visits of the international consultants no restrictions were observed and all questions were answered freely and candidly. During the assessment however some limitations in obtaining data were observed for example when the stack has not sampling hole or when the factory has not a significant down time to establish pressurized air losses in the system.
2.5.4 EMS
Other than the basic waste management procedures hardly any environmental management systems are operative in the textile industry. Establishing the CP team was for most companies the first step in establishing an organizational structure to address environmental issues.
2.5.5 WASH
Overall speaking the quality of the drinking water and the number of toilets for men and women are considered sufficient. Some companies provide cold water and rehydration pills when temperatures exceed certain limits.
2.5.6 Chemical inventory and banned chemicals
All factories visited have signed compliance statements regarding banned chemicals as well as asked these from their suppliers. Some chemical inventories can be improved especially when it concerns sub stores (working quantities in the factory). In the main storage MSDS and emergency equipment is available but missing in the sub stores. Handling and spill control can be improved. Personal protection equipment and especially safety boots and aprons in the wet section can be improved in few companies.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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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.
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
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2.10 Capacity Building of Local Consultants At the start of the project the local consultants received training on how to implement the assessment. The training consisted of two parts, a classroom training and hands-on training at 6 companies. The class room training consisted of modules concerning:
General CP training and exercises
Textile engineering
Mechanical Engineering in textile processing
Chemical engineering in textile processing
Electrical engineering in textile processing For OHS, EMS and WASH self-explaining worksheets have been prepared which have been discussed with the local service providers designated staff. Prior to the start of the project the local service providers have received training in WASH and water footprint calculations. During the hands-on training at the 6 companies the local service providers learned to identify options, learned how to calculate data when (factory) meters are absent, consultancy skills, etc. All items were thoroughly discussed and the approach tailored to the local situation. After the 6 company visits the complete team was gathered in the class room to evaluate the visits and develop the action plans.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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3 Cleaner Production Implementation
3.1 General Overview 50 companies participated in the basic CP assessments. The type of activities in the wet processing section are dyeing (yarn, knit, woven) and washing (garments and denim). Production output and number of workers are listed to illustrate the size of the wet processing activities.
# Factory name Type of factory
Wet process capacity in ton/month unless specified otherwise
Working days/year
Number of workers (wet process only)
01 Unicom Textile Yarn dyeing and woven dyeing
425 340 250
02 Textown Textile Knit dyeing 312 340 208
03 Ring Shine Textile Yarn dyeing 1,841 340 1,726
04 HR Textile Knit dyeing 482 340 271
05 Noman Terry Towels Yarn dyeing & towel production
1,870 340 670
06 ARS Washing Ltd. Washing 781,000 pcs/month 340 95
07 Abanti Knit dyeing 700 340 410
08 Fariha Knit dyeing 1,133 340 445
09 Graphics Knit dyeing 340 340 302
10 Iris Fabrics Knit dyeing 3,309 340 253
11 Windy Washing Washing 975,000 pcs/month 340 100
12 Karooni Textile Knit dyeing 538 340 364
13 Norban Comtex Knit dyeing 285 340 330
14 Mondol Knit Tex Knit dyeing 240 340 100
15 Evince Textile Dyeing 270 340 375
16 Reedisha Knit dyeing 480 340 480
17 Aman Knit dyeing 720 340 459
18 Thermax Yarn dyeing 300 350 862
19 EOS Fabric dyeing 600,000 m/month 350 194
20 Regency Washing 300 297 660
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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21 Intramex Yarn, woven & knit dyeing
480 296 1,041
22 Paramount woven dyeing, yarn dyeing
Fabric: 1.3 million m/ year
Yarn: 720
252 231
23 Etafil accessories LTD. (yarn dyeing unit of Tamishna)
Yarn dyeing 960 340 174
24 Russel Washing 600,000 pcs/month 296 18
25 Maxcom Denim washing 15,000 pcs/ month 326 101
26 JM Fabrics Knit dyeing 390 352 100
27 Genesis Washing 600,000 pcs/month 282 76
28 Libas Knit dyeing 480 313 355
29 ATS Denim washing
Garments: 650,000 pcs/month Denim: 300,000 pcs/month
302 30
30 Taqwa Washing 360 340 197
31 Pioneer Sweater garments washing
50,000 pcs/day 296 607
32 Partex Denim Denim washing, dyeing
1,000 360 210
33 Bengal Hurricane Knit dyeing, printing 600 300 244
34 Newage Textiles Knit dyeing 360 350 250
35 Denim Expert Washing 180 290 168
36 Unifill Composite Woven dyeing 630 300 343
37 Fashion Forum Washing 425 300 350
38 Esquire Knit Knit dyeing 524 286 660
39 Meghna Knit Knit dyeing 632 345 350
40 Modele De Capital Washing 425 300 380
41 East West Suiting Sweater garments washing
10o 300 53
42 Envoy Textiles Woven dyeing 1,050 355 163
43 P. N. Composite Knit dyeing & washing 352 352 251
44 Saiham Knit Knit dyeing 300 300 164
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
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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.)
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
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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
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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
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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
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
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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
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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
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
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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
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
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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
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
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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.)
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.)
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
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
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
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
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
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
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
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
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
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
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
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)
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
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
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
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
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.)
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
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
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
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
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
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)
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
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
76
3.3 Financial Impacts of the Pilot Project In the 50 CP company assessments 545 options were recommended which may incur an estimated total investment of 5,626,789 USD with which an total potential benefit of 3,605,020 USD can be obtained. The estimated payback was on average nineteen months. After a six month monitoring period it was concluded that 185 options (34% of the suggested/agreed recommendations) have been implemented with a total investment value of 1,592,909 USD and generating economic benefits of 768,020 USD per year. Simple payback of the investment is 2 years.
3.4 Resource Saving and Environmental Benefits Within the monitoring period 185 options out of 545 identified options have been implemented by the 50 companies which have generated the following resource savings and environmental benefits. Water consumption The 50 companies managed to reduce their water consumption with 1.97 million m3 which is over 5% of the original annual consumption 38.1 million m3. Of the 1.97 million m3 reduction 1.59 million m3 was obtained in the wet textile processing units.
Natural gas The 50 companies managed to reduce their natural gas consumption with 10.3 million m3 which is approximately 3% of the original annual consumption 404 million m3. The corresponding financial value of the NG saving is 645,109 USD Electricity The 50 companies managed to reduce their electricity consumption with 10,389 MWh which is approximately 2% of the original annual consumption 288,284 MWh. Saving resource is equivalent to 1.64million USD per year. Steam The 50 companies managed to reduce their steam consumption with 34,389 ton which is approximately 1.33% of the original annual consumption 2,617,187 ton Greenhouse gases The 50 companies managed to reduce their greenhouse gases generation with 20,946 ton which is approximately 3% of the original annual generation of 794078 ton Wastewater The 50 companies managed to reduced their wastewater generation with 1.59 million m3 which is approximately 5% of the original annual generation of 28.9 million m3.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
77
3.5 Qualitative Changes Apart from the implementation of the options which yielded quantitative benefits also changes
have been made which improved safety, working atmosphere etc. Most factories made positive
changes in following areas:
Improving floor markings and housekeeping conditions.
Redesigning Chemical storage for safe storage of chemicals as well as to ensure good
handling and spillage control.
Ensuring proper labeling and signage at work places.
Providing rubber mats in front of electrical panels to ensure people safety.
Developing new standard operating procedures.
Awareness raising and motivating workers to practice energy and water saving
continuously.
Provide training to ensure a shift of mindset towards CP practices.
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
78
4 Cleaner Production Calculation Methodology
4.1 General Overview
Assessing the technical feasibility, financial viability and environmental desirability of CP options is
important to identify feasible CP solutions. The selection of a CP solution for implementation requires
that it should not only be techno-economically viable but also environmentally desirable.
The technical evaluation determines whether a proposed Cleaner production option will work for the
specific application. A CP option that is not technically feasible cannot be converted to an
implementable solution. Once the option is confirmed as technically feasible, the environmental and
financial viabilities are assessed.
Quantification of the CP options is key to the success of the CP assessments. The expected savings for
the options, both in terms of resources and the monetary, is looked at by the factories to decide upon
their implementation. This chapter presents the calculations used to estimate the savings expected from
the CP options.
4.2 Thermal System
The boiler is main thermal utility used in textile processing. The steam generated from the boilers is
used as the source of heat in the processes. Natural Gas (NG) is the energy source used in boilers. The
steam generated is transferred through insulted pipelines which are equipped with steam traps for
maintaining the steam quality.
In some operations steam is used directly while in others it is used indirectly to achieve heat transfer. In
operations where steam is used indirectly the condensate generated is expected to be recovered and
reused back in the boiler as feed water. The heat content of the condensate helps in reducing the NG
consumption.
For the various CP opportunities related to thermal energy identified under this project, the calculation
methods used for estimating the savings are given in the following sections.
4.2.1 Savings from Steam Line Insulation
Insulation reduces heat loss in steam through piping and valves by repairing or adding insulation.
Savings Calculations:
Surface Temperature
difference (0C) =
Surface Temperature
without Insulation (0C) -
Surface Temperature with
Insulation (0C)
Heat Loss from uninsulated
pipe (kW) =
Heat loss factor at surface
temperature difference
(kW/m)and pipe diameter
X Length of uninsulated pipe
(m)
Total Heat Loss Per Day
(kWh) =
Heat loss from
uninsulated pipe 1
(kW)
+ …. + Heat loss from
uninsulated pipe n
(kW)
Final report: Promoting Cleaner Production in the Washing/Dyeing Finishing Sector in Bangladesh, A project under the Partnership for Cleaner Textile program, IFC contract 7170521
79
X Number of Working Hours (h)
CNG saving per day (m3) = Total Heat Loss per
day(kWh) /
Calorific Value of CNG
(kJ/m3)
Financial saving/day (BDT) = CNG Saving per day (m3) X Cost of CNG (BDT/m3)
Financial saving /Annum
(BDT) = Financial saving/day (BDT) X
340 days (working days
per annum)
4.2.2 Savings from Condensate Line Insulation
Condensate line Insulation reduces heat loss from condensate through piping by repairing or adding
insulation.
Savings Calculations
Surface Temperature
difference (0C) =
Surface Temperature
without Insulation (0C) -
Surface Temperature with
Insulation (0C)
Heat Loss from uninsulated
pipe (kW) =
Heat loss factor at surface
temperature difference
(kW/m)and pipe diameter
X Length of uninsulated pipe
(m)
Total Heat Loss Per
Day(kWh) =
Heat loss from
uninsulated pipe 1
(kW)
+ …. +
Heat loss from
uninsulated pipe n
(kW)
X Number of Working Hours (h)
CNG saving per day (m3) = Total Heat Loss per
day(kWh) /
Calorific Value of CNG
(kJ/m3)
Financial saving/day (BDT) = CNG Saving per day (m3) X Cost of CNG (BDT/m3)
Financial saving /Annum
(BDT) = Financial saving/day (BDT) X
340 days (working days
per annum)
4.2.3 Steam Trap
Drain Points are part of the steam network which are installed for removing water in the pipes
accumulated due to condensation of steam. The presence of water causes water hammering. Steam
traps are provided at the drain points to avoid leakage of steam.
Following table gives selection guide for steam trap installation for various applications.
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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.
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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.
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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
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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)
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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.
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4.6 Factory Provided Saving (not specified)
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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
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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
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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
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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
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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
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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
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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:
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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
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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:
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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.
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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.
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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):
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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
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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.
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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.
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
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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.
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
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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
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