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SouthAsia Enterprise Development Facility
Promoting Cleaner Production in the Textiles Sector
May 9, 2011
•Yarn •Knitting •Fabric Dyeing •Cutting & Making
•Spinning •Weaving•Washing
•Finishing
•Export
•Cotton
Value Chain
•1700 units 1700 units employing 200,000 workers
•Growing at 10% per year
•Net value addition 12-20%
Objective of the CP Intervention
Improve waste management and production
efficiency of the WDF firms by demonstrating the
benefit of adopting cleaner production (CP),
capacity building of service providers &
stakeholders.
Benefits of Using Cleaner Production
• Reduced operating cost and improved productivity
• Improved company image-better market access
• Reduced environmental impact and reduced risks and liability
• Opportunity to gain access to finance
• Increased worker productivity due to having better process controls in place
Overview of the Program
International Consulting Firm (NEC)
Local Consulting Firms (Adroit & Reed) Capacity Building
• Program approach at factory level
• Baseline assessment
• Identify areas of improvement (short/medium/long)
• Support factories to implement CP options (training, consultancy, user group)
• Evaluation
• Industry wide uptake through replication
IFC SOLIDARIDAD BRANDS
Partners-Factories • ABA GROUP
• COMPTEX BANGLADESH LIMITED
• COSMOPOLITAN INDUSTRIES (PVT) LIMITED
• FAKIR KNITWEARS LIMITED
• HAMZA TEXTILES LIMITED
• INTERSTOFF APPARELS
• KNIT CONCERN LIMITED
• LIBERTY KNITWEAR LTD
• MULTIFABS LIMITED
• S.F.FASHION LIMITED
• TARASIMA APPARELS
• UTAH KNITTING & DYEING LTD
• NAZ FASHIONS
• ELEGANT FASHIONS
What is User Group
12
•Members of different companies talk about one topic
•Motivated to
Improve
Save
Reduce costs
•Open discussions with implementers
•Action
•Share results
Actions in a User Group
• Define the problem
• Study literature (what is out there?)
• Do measurements (where are we now?)
• Determine the influences/parameters
• Define improvements
• Implement improvements
• Stimulate and monitor follow up actions
• Defining results of the actions
• Benchmarking
• Evaluation
13
CP Program approach at factory level
•Clarification on data •All data based on audit days
•and any other left over data
•Submission and Presentation of audit report
•Evaluation of report by Client
•Comments from clients
•Preparation of Report
•Data Analysis •Secondary Data
•Pre-Audit Assessment•One-one meeting
•Final Report preparation & Submission
•Questionnaire Check list
•Sampling Data Gathering
•Filling survey questionnaire
•Audit Field Work
•Dates Finalized•Finalized
•Debriefing
•Action Plan•Implementation Team Formation•Monthly Follow
Up
Common findings from pilot factories from pilot factories
• Wastage of water- as usage is 15-18% higher than is required
• Data constraints
limited benchmarking of usage patterns limited use of flow meters (gas, water)
• Potential for insulating pipelines, valves
• Potential to replace faulty steam traps
• Potential to replace magnetic ballasts in lighting system
• Potential to standardize the storage and disposal of waste
Potential Areas Of Cost Savings
•Chemical storage &handling improved in allfactories •Spillage management •procedure developed •for 8 factories
•1482 m of different sized •steam and condensate •Pipeline has been insulated•with estimated cumulative •Savings of BDT 51 lakh
•30 steam traps have•been repaired or replaced •with estimated cumulative •Savings of BDT 25 lakh
Mutually agreed upon action plan Recommendation Update as of April 2011 Budget
Allocated BDT
Potential Savings
Benchmarking of Resource Utilization with Respect to Quality & Process of Fabric
Started working. Initially water related losses or leakages. Trying to reduce water use from 350 liter to 250 liters
1,00,000/=
Chemical Storage and Handling Improved infrastructure e.g: fit exhaust fan and maintaining good house keeping
Completed
Lighting, Ventilation and Exhaust Systems Purchased 14 exhaust fans, Working on ventilation. Procure 7 fans and 5 fans will be fitted at the dyeing section, 1 fan at the thermal boiler, 1 fan at the steam boiler
2,45,000/=
Noise Pollution Control already doing it at generator
Air Pollution Monitoring Stack analyzer has been purchased 2,60,000/=
Action plan-continuedWater Flow Meters 4 additional water flow meters are
installed, flow meter installed at WTP and Dyeing floor section
Steam Flow Meters 4 to be purchased into 4 main departments within dyeing department.
Power factor improvement for self generation PFI installed and waiting for the connection to factory supply line. REB PFI installed and pf improved. Operating pf is .81 tp .82 now.
3,40,000 86,666/mon
th
Realized & Pipeline Investments
20
• Already Invested• Power Factor controller,
Ventilation system, Steam-line leakage & insulation etc.
5,961,000BDT
• Pipeline investments planned • Heat Recovery System of Stenter,
Economizer for Boiler and Flow-meters for Water & Steam etc.
9,720,000BDT
CP Program-Key areas of savings
94,769
50,000
6,073
2,000
86,449
Mechanical Maintenance
Steam Traps
Condenate Recovery
Cooling Water
Power Factor Improvement
BDT/month USD /month
Mechanical Maintenance 94,769 1,316
Steam Traps 50,000 694
Condenate Recovery 6,073 84
Cooling Water 2,000 28
Power Factor Improvement 86,449 1,201
Synergies and Scale up
• Partnership with local bank to increase exposure on EE lending
• 27 bankers participated in walk-through in participating factory
• 2 day CP training program held for bankers
• Communication strategy to disseminate findings to industry wide audience for scale up
Conference in Copenhagen
“Negotiators cannot do this alone, nor can politicians,the ultimate responsibility rests with the citizens ofthe world, who will ultimately bear the fatalconsequence if we fail to act”
Lars Loekke Rasmussen
Prime Minister of Denmark
25