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How clean your production is?

As per as energy & raw materials is concerned, the earth is quickly going out of stock. You may be very much optimistic that there will be new alternative sources for those. Growing population and increased consumption per person and all together the scarcity mentioned above are the basic challenges for sustainability. But as an industry we are always under pressure to make profit. So, here it is very much straight forward, “The more you are clean, the more you are profitable”. So for you, believe me “How clean your production is?” is a very big question. So, the term to talk about is “Cleaner Production (CP)”. Though it is not a new word, it is really not at all considered in our textile and garment industry with due diligence. The best our industry has done is some work on “House Keeping”. So, to have clear idea about CP is very important.

Currently World Bank and its group are running two projects in the textile industries. One project is being anchored by International Finance Corporation (IFC) and another one is anchored by Natural Resource Defense Council (NRDC), an US based nonprofit NGO. Both the projects came through walk through study, factory selection, factory assessment & evaluation, identifying CP practices and implementing those. The projects are almost at the end of the implementation stage now. Currently the bank was sharing the preliminary data of the NRDC project with the industry people in a workshop. The workshop was a tremendous success with the participation from all streams of the industry. The cover story is on the workshop.

CP means 4R which are Reduce, Reuse, Recover & Recycle. It is in fact conservation in everything. As materials and energy costs money, if you conserve, it is directly savings. This is the extra amount you can make in this tight business world. Cleanliness interestingly will improve productivity, efficiency. It will improve your social compliance status and more importantly your organization and human resource also will become more effective and goal oriented. But the question is how much you afford to invest for CP. The amount of savings definitely will be lucrative enough to give you pay back in few months.

The energy our wet processing industries using are power & steam. Water & chemical are the materials that are in big use to process the fabric. As fiber price is very high, you are never crazy enough to waste that. Overall material loss is very less in our country. But still there are opportunities to look at. Improving marker efficiency, reducing process waste, avoiding operations that cause fiber loss, reusing cutting room wastage & exhausted cone yarns etc. can be some important area to work with. In general we keep 5-10% extra fabric/yarn, but it is the time to look at more cautiously to reduce that amount. Energy cost is increasing and for most of the factories it is just not abundant to us. The amount of energy we save is the extra fabric we can process with that saved amount. A very big loss occurs in our industry is of steam. If we don’t recollect the steam condensate, immediately need to do that. How much it will cost to maintain the steam traps properly? We cannot imagine how much we are losing for that? Insulating the pipes can give significant savings. Boiler performance can be increased by adding a very small magnetic device at the inlet water pipe to eliminate chemical use in the boiler inlet water. Using automatic blow down mechanism is feasible. But at any how if we can’t fix up the steam system, we need to lock the system by reusing flashed out steam to pre heat water. Those preheated water can be used in the dyeing machine and at the boiler inlet as well. Cooling water coming out from heat exchanger is the big amount we can save as well by just sending that back to the pre heat tank.

The chemical you use is of big cost, so we have clear effort to save those. But still by considering the spillage losses we can increase our savings. Adopting new high performance chemicals & process can be lucrative also. Water is the cheapest material we use but in consolidation it is the most we lose. In conception water is free but if you add back pumping, softening and effluent treatment cost, the loss is really big. Over flow rinses in the process is the biggest user of water, open hose pipes with the machine are the cause of considerable loss, achieving best possible Material: Liquor etc are things to get serious attention.

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

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