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How ACS Textiles turns sustainability into profitability?

ACS Textiles is a 100% British investment established in 2004. It is a name emblematic of trust and superior quality in Home Textiles. As a state-of-the-art composite manufacturing facility with weaving, dyeing, printing, finishing, and packaging services, all offered under a single expansive roof, ACS stands as one of the largest of its kind in the industry.

ACS Textiles BD Ltd is an award-winning environmentally conscious company, the company sets sustainability practices as the core of the business. The company found sustainability as profitability in different magnitude. Recently the company became the first ‘Zero Discharge of Hazardous Chemicals’ (ZDHC) contributor from Bangladesh to use their expertise to help create and develop ZDHC standards, tools, guidance, and training. Stockholm International Water Institute (SIWI) Award 2016 also awarded the company for outstanding achievement in sustainable water management and certificate of participation.

ACS Textiles BD Ltd

While minimizing environmental impact, the company succeed to lower its cost of operation. Recently they received the GRS certificate for their successful footprint in recycling.

Mission statement board of ACS Textiles Ltd.
Figure 1: Mission statement board of ACS Textiles Ltd.

Energy management to reduce electricity usage
The company is minimizing its total energy consumption significantly. In 2017, they saved 37.07% of energy and set a target to reduce further consumption by 45% up to the year 2020. The measures are described below-

  1. The company replaced fluorescent tube to LED tube light, already installed 4500 pcs of LED lights.
  2. For proper utilization of ‘daylight’, the company installed UV protecting fiberglass sheets. That eventually turned off 456 pieces of LED lights nine hours per day.

    ACS Textiles BD Ltd Solar Panel
    Figure 2: ACS Textiles BD Ltd has a plan to install 300 KWh capacity solar panel by 2020.
  3. They have already replaced clutch motor by Servomotor in the sewing machine. Total
    654 pieces of servomotor are installed that save up to 152064 KWH energy. For efficient electricity control, they have installed 60 pieces of PRI sensor that saves up to 21600 KWH of electricity per year. To reduce energy consumption in the office Air Conditioning system, they have installed three pieces of inverter controlled Air Conditioner with ECONAVI technology, which saves 50-60% Energy.
  4. The company also plan to install 300 KWh capacity solar panel by 2020 that will allow the company to reduce the carbon footprint significantly. Also, they have planted 900 trees in factory premises and the above measures in total reduce 72% of CO2 emission by September 2018.

Process and heat energy management

Till 2017 they have saved 34.57% of heat energy and set a target to save 40% within 2020.
Caustic recovery plant has been set, which can save up to 98% of caustic soda from the
mercerizing process. This could save up to 330000 m3 of water per year. That means 66000 kWh energy saved in 2017. This process allows less TDS on ETP and less environmental impact and economic benefit for ETP management. The company has installed 3 sets of condensate recovery systems, thus about 90% of feed water for the boiler is reused at 85~94 degree Celsius, saving on consumption of water, chemicals as well as gas for burners.

Exhaust heat exchanger ACS Textiles Ltd.
Figure 3: Exhaust heat exchanger.

They also have installed a heat exchanger in the exhaust of 5 generator engines for supplying hot water to the fabric dyeing section, thereby saving about 4 tons of steam that would have otherwise been required for the heating of water. One more waste heat recovery boiler is being ordered for utilizing heat energy from 4 more gas generators.

Read More: Death benefits for RMG workers- the story of ACS Textiles Ltd.

In the dyeing machine, they have installed heat exchanger, drained hot water after dyeing is supplied for pre-heating of feed water circulating through coils fitted in the feed water tank where latent heat of condensate is utilized.

Waste management for ensuring reduce, reuse and recycle (3R)

Till 2017 their 3R process reduced 5% of wastage and set a target to reduce 49% within 2020.

The company is converting pillowcase from waste cut pieces by an in-house facility and finally rejected/wasted cut pieces are delivered to Dipu Enterprise (waste contractor) for recycling. All attendance register, leave register and others are maintained by software documentation and internal communication also conduct by mail instead of a memo,
and wasted papers are sent to Sonali Paper Mills for recycling by Rahat Enterprise Waste

Unused surplus and wasted sewing thread are sorted by color wise for reusing and spare threads are converted to solid color by in-house yarn dyeing facility.

Caustic Recovery Plant ACS Textiles BD Ltd
Figure 4: Caustic recovery plant.

Water and ETP Management

Till 2017 they minimized 14.91% of water consumption and set a target to reduce 20%
within 2020.

ACS has established 24/7 fully functional biological ETP plant with Joseph EGLI Italia for ensuring efficient water and wastewater treatment by advanced biological treatment, water, and wastewater reuse by membrane filtration and composting of biomass.

The company is also harvesting a huge amount rainwater in the rainy season. In August and September 2018, they have harvested 624000 liters of rainwater.

The company employs over 6000 people and average daily production capacity is 30,000
pieces of superior quality textile products. The products have found their market in European countries such as Italy, France, and the UK also in Scandinavian Europe with its design studio in Sweden for famous brands like HEMTEX, H&M, Sainsbury’s, Loblaws, Bed Bath N’ Table, Sodahi, Dorma, Laura Ashley, Hoie, Adidas, Descamps and Dunel etc.

Also Read: How sustainability practices help Envoy Textiles Limited to go on top.

If anyone has any feedback or input regarding the published news, please contact: info@textiletoday.com.bd

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