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Energy Made-to-Measurein textile and clothing industry

Energy Saving tools for Textile/Clothing Manufacturing

A quick introduction

Samuele Branchetti – ENEA CROSS-TEC

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Outline

• Energy Saving Scheme (ESS) EDST EMBT SAT

• Energy Consumption Reduction Tool Consumption analysis Investment evaluation

• Examples

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Energy Saving Scheme (ESS)

The Energy Saving Scheme ESS is supported by three Excel based tools, which are:

• Energy Distribution Support Tool – EDST

• Energy Management and Benchmark Tool – EMBT

• Self Assessment Tool – SAT

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EDST- Energy Distribution Support Tool

• How and where is energy being consumed?

To understand the organization’s energy matters the best tool is an energy audit, which should be conducted by internal or external specialists by means of consulting.

If an audit is not feasible, an internal approach can be made in order to access energy flows using the EDST.

The EDST allows to input technical and work load data and produces the electrical and thermal energy distribution by use type and productive process/section.

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EMBT - Energy Management and Benchmark Tool

• What is the energy content of my product?• What is the carbon footprint of my product?• How can I evaluate my consumption on a regular basis?• How is the company performing, energy wise, when compared

with its counterparts?

The EMBT allows to match the company’s energy bills and production data to calculate energy indicators and report on the evolution of consumption:

• regression analysis (energy vs. production charts)• benchmark, based on data collected in five countries, Bulgaria,

Germany, Italy, Portugal and Romania• monitoring of energy indicators by continuing to use the tool

month by month and checking evolutions

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SAT - Self Assessment Tool

A tool for an energy check-up:

• to analyze the energy consumption of own company

• to select a list of energy saving measures and costs reduction

• to evaluate the saving achieved by energy efficiency improvement

• does not replace an energy audit conducted by specialists

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SAT / ENCORE

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SAT / ENCOREConsumption analysis

• It provides energy consumption and cost indicators compared to benchmarks for each kind of production: consumption and cost / turnover (Eurostat benchmarks) energy consumptions distributed by source specific electrical and thermal consumption by

product/productive process (ARTISAN benchmarks) total CO2 emissions

• It identifies saving measures to reduce energy consumption: list of recommended Best Practices

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SAT / ENCOREDownload

http://www.euratex.eu/sesec

http://www.artisan-project.eu/?q=3&TR=D

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SAT / ENCOREConsumption analysis

Example: a clothing company

• sewing machines and ironing presses• turnover of Euro 17.000.000,00• production of 200.000 units• electricity and natural gas consumption

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SAT / ENCOREConsumption analysis

Example:

company that leads a steaming process of yarn

• finishing activities• high using of thermal energy• customized products• turnover of Euro 2.000.000,00• electricity and natural gas consumption

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Plan-Do-Check-Act cycleA

udit energetico

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ENCOREInvestment evaluation

• Is the energy efficiency improvement profitable?

A specific module is available to make a cost-benefit analysis:

• for assessing the ability of an investment to offer a net benefit

• to select the best choice out of many solutions• costs and benefits estimated in monetary terms

and discounted for the time value of money

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ENCOREInvestment evaluation

NPV – Net Present Value

IRR – Internal Rate of Return The rate that sets the NPV of the cash flows equal to zero (the discount rate at which the costs equals the benefits)

DPB – Discounted Payback Period The amount of time that sets the NPV equal to zero, i.e. the years required to cover the cost of investment

PI – Profitability Index The amount of value created per unit of investment

Sensitivity analysis The variation in the NPV under different values of input Ti, CF, n e Io

𝑁𝑃𝑉=𝐶𝐹 ∙∑𝑗=1

𝑛

[ 1(1+𝑇𝑖 ) 𝑗 ]− 𝐼 0

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ENCOREInvestment evaluation

Example: cogeneration improvement

Present situation Ameliorative situation A

Revamping of cogenerators

Ameliorative situation B

Replacing of cogenerators

Cogeneration plant that includes n.2 identical cogenerators running since 15 years

Need of an in-depth updating

Updating of cogeneration units in order to bring them back to the rated operating conditions

Replacement of cogenerators with new plants that provide the same rated power

Efficiency to 33-34%due to wear

Efficiency to 37% Efficiency to 40%