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CP Assessment Report Target Fine Wear Industries Ltd
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 1
Bangladesh Water PaCT:
Partnership for Cleaner Textile
Cleaner Production Assessment Report
Prepared for:
Target Fine Wear Industries Ltd.
Alauddin Chowdhury Tower, Chandona, Chawrasta,
GazipurSadar, Gazipur
Prepared by: Bangladesh Centre for Advanced Studies (BCAS), Gulshan, Dhaka.
Supported by:
Asia Society for Social Improvement and Sustainable Transformation (ASSIST)
January 2016
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 2
Acknowledgement
BCAS Team acknowledges with gratitude to Md. Lutfor Rahman, Director, Finance & Administration
and his team of Target Fine Wear Industries Ltd for the excellent co-operation during the visit and for
providing necessary information to carry out the assessments.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 3
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, build factory capacity, technical knowledge, and access to finance for
investments for Cleaner Production, and create a platform for community and national dialogue on
sustainable use of water in the textile sector.
IFC has commissioned Asia Society for Social Improvement and Sustainable Transformation
(ASSIST), India to support the local service provider Bangladesh Centre for Advanced Studies (BCAS)
based in Dhaka, Bangladesh for the execution of 50 basic CP assessments.
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.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 4
List of Acronyms and Abbreviations
BCAS Bangladesh Centre for Advanced Studies
BDT Bangladeshi Taka
BOD Bio-chemical Oxygen Demand
COD Chemical Oxygen Demand
CPA Cleaner Production Assessment
dB Decibel
DOE Department Of Environment
EMS Environmental Management System
ETP Effluent Treatment Plant
GHG Green House Gas
GHS Global Harmonizing System
IFC International Finance Corporation
kVA Kilo Volt Ampere
kW Kilo Watt
kWh Kilo Watt Hour
MSDS Material Safety Data Sheet
MWh Mega Watt Hour
NG Natural Gas
OHS Occupational Health & Safety
PFI Power Factor Improvement
pH Power of Hydrogen
PPE Personal Protective Equipment
REB Rural Electrification Board
TDS Total Dissolved Solids
TSS Total Suspended Solids
VFD Variable Frequency Drive
WASH Water sanitation & hygiene
WHRB Waste Heat Recovery Boiler
WTP Water Treatment plant
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 5
Executive Summary:
Target Fine Wear Industries Ltd. is a textile-processing unit (Flat Knit Sweater and Jacquard Sweater)
of cotton, polyester/cotton blended fabric. The factory has knit washing average production of
585,417pcs per month (from data of 2015).
Except wet process, the factory has set up knitting and stitching units within the same premises. The
units run for approximately 300 days in a year over 2 shifts per day. The total number of workers in the
factory is about 1800. Only washing section is about 400 workers (1 shift).
Resource and Energy
The resource and energy consumption summary is given below:
Parameter Unit Annual
consumption Remarks
Water Consumption m3/year 41,334 Based on factory provided data
Natural Gas consumption m3/year 262,811 Based on data provided by the
factory
Diesel Consumption Litre/year 25,964 Based on factory provided data
Power consumption kWh/year 1,292,815 Based on factory provided data
*Based on 2015 data
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 6
Assessment outcomes:
The Cleaner Production Assessment at Target Fine Wear Industries Ltd showed that significant
reduction could be achieved in water (27%), power (22%) and natural gas (26%) consumption. Based
on the findings of the CPA, the consortium identified 13 cost-effective measures for achieving
significant water and energy reduction.
The summary is given below:
Area Total number
of options
Estimated
investment,*USD
Economic
benefits,
USD/year
Environmental benefits/year
Process 6 1,100 2,405
Water saving: 10,997 m3
Power Saving: 19,734 kWh
NG saving: 3,740 Nm3
GHG reduction: 31.65 tons
Utility 7 39,200 36,777
Power saving: 268,633 Nm3
NG saving: 65,417 Nm3
GHG emission reduction
303.7 tons
Total 13 40,300 39,182
Water Saving: 10,997 m3
NG saving: 69,157 Nm3
Power Saving: 288,367
kWh
GHG emission:335.35 tons
*1 USD = BDT. 78.00
KPI:
Implementing the improvements leads to the following reductions in the consumption of dominate
sources:
Parameter (based on
2014 data) Unit
Current
consumption
Future
consumption
Reduction
%
Water consumption m3/year 41,334 30,337 27
Natural Gas consumption m3/year 262,811 193,654 26
Power consumption kWh/year 1,292,815 1,004,448 22
*Based on 2015 data
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 7
Cleaner Production Measures:
The details of the option generated in different areas are given in the table below:
# Measure
Estimated
investment,
USD
Economic
benefits
USD/year
Environmental
benefits/year
Payback
time,
Months
Process Area
1.
Calibration of different
gauges and meters utilized in
processing area.
Minimum Easy to
monitor Indirect Savings. -
2. Installation of level indicator
in the washing machines 100 -
Reduction of
wastage of water Immediate
3. Optimization of dryer time in
washing section 500 290
NG savings: 3,740
Nm3/year possible
GHG reduction:
7.1 ton/year
21
4. Monitoring liquor ratio for
washing Minor 1,493
Water savings:
7,765 m3/year
Power saving:
15,448 kWh/year
GHG emission
reduction: 10.35
tons/year
Immediate
5. Reusing the discharged water
from hydro-extractor 500 622
Water saving:
3,232 m3/year
Power
saving:4,286
kW/year
GHG emission
saving: 2.87
Tons/year
10
6. Promoting the concept of
“zero discharge
To be
estimated Long
Water saving:
12,748 m3/year
Power saving:
16,907 kW/year
GHG emission
Long
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 8
# Measure
Estimated
investment,
USD
Economic
benefits
USD/year
Environmental
benefits/year
Payback
time,
Months
saving:11.33
Tons/year
Total 1,100 2,405
Water saving:
10,997 m3/year
Power Saving:
19,734 kWh/year
NG saving: 3,740
Nm3/year
GHG reduction:
31.65 Tons/year
5.5
Utility Area
1. Installation of energy
efficient lights 23,077 17,539
Power saving:
181,440
kWh/year
GHG emission
reduction 121.56
tons/year
16
2. Installation of energy
efficient motor 577 324
Power saving:
3,352 kWh/year
GHG emission
reduction 2.25
tons/year
21
3.
Installation of Servo Voltage
Stabilizer on lighting load
Circuit
11,026 8,105
Power saving:
83,841
kWh/year
GHG emission
reduction: 56
tons/year
16
4.
Installation of energy meters
to monitor specific energy
consumption
- - Indirect saving -
5. Proactive Maintenance of
Electrical Systems - -
Increase life
time.
Reduce
breakdown.
-
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 9
# Measure
Estimated
investment,
USD
Economic
benefits
USD/year
Environmental
benefits/year
Payback
time,
Months
Indirect saving.
6. Installation of condensate
recovery system 2,000 2,494
NG savings:
26,281 m3/year
GHG emission
reduction: 50
ton/year
10
7.
Minimizing Heat Loss by
proper insulation of bare
surface, pipes, valves and
correction of steam leakages
and traps.
2,520 8,315
NG saving:
39,136
Nm3/year
GHG emission
reduction: 73.9
ton/year
04
Total 39,200 36,777
Power saving:
268,633
Nm3/year
NG saving:
65,417
Nm3/year
GHG emission
reduction 303.7
tons/year
13
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 10
Table of Content
Acknowledgement ........................................................................................................................ 2
Executive Summary: .................................................................................................................... 5
1 Introduction .......................................................................................................................... 12
1.1 Company overview......................................................................................................... 12
1.2 CP Team ......................................................................................................................... 13
2 Overview & Current Baselines............................................................................................. 14
2.1 Description of production processes .............................................................................. 14
2.2 Main Inputs..................................................................................................................... 16
2.2.1 Water ..................................................................................................................... 16
2.2.2 Energy ................................................................................................................... 18
2.2.3 Process Chemicals: ................................................................................................ 20
2.3 Main Equipment ............................................................................................................. 21
2.4 Waste streams ................................................................................................................. 22
2.5 Water Footprint .............................................................................................................. 23
2.6 Water Sanitation & Hygiene (WASH) ........................................................................... 23
2.7 Occupational Health & Safety (OHS) ............................................................................ 25
2.8 Environmental Management System (EMS) .................................................................. 27
3 Assessment and CP options .................................................................................................. 28
3.1 Opportunities in process areas ........................................................................................ 28
3.2 Opportunities in utility area:........................................................................................... 31
3.3 Opportunities in Water Sanitation & Hygiene (WASH) ................................................ 35
3.4 Opportunities in Occupational Health & Safety (OHS) ................................................. 35
3.5 Opportunities in Chemical Inventory ............................................................................. 36
3.6 Solid Waste Management System .................................................................................. 36
3.7 Opportunities in Environmental Management System (EMS)....................................... 37
4 Conclusion ............................................................................................................................ 38
4.1 Impact Summary of Measures Recommended ............................................................... 38
4.2 Impact Measures on Savings (Percentage Reduction) ................................................... 39
5 Annex
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 11
Table of Figures
Figure 1: Production process sequence ................................................................................................... 14
Figure 2: washing Process sequence ....................................................................................................... 15
Figure 3: Water Balance Diagram ........................................................................................................... 17
Figure 4: Electrical Energy Balance Diagram ......................................................................................... 19
Figure 5: Steam balance diagram ............................................................................................................ 20
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 12
1 Introduction
1.1 Company overview
Company name: Target Fine Wear Industries Ltd
Address:
Head Office Factory
House #06, Road #10, Sector # 04, Uttara
Model Town, Dhaka 1230, Bangladesh
PABX : +88 02 8931158, 8915965
Email : lutfor@targetgroupbd.com
Alauddin Chowdhury Tower,
Chandona, Chawrasta,
GazipurSadar, Gazipur.
Year of establishment: 2009
Company structure: Target Group is a medium group. This company includes Target Fine Knit
Industries Ltd and Time Sweaters Ltd etc.
Production overview: Target Fine Wear Industries Ltd Sweatersstarted industrial operation by setting
up sweaters process under the umbrella of Target Fine Wear Ltd. Sweaters ltd in Bangladesh in the year
2009.The factory had continuous expansion going on over the years and each year, the capacity and
production increased gradually.
Clients: The major clients are Genifer, H&M, Primark, Grausam.
Expansion plan: The Company does not have any expansion plan yet.
Number of employees: Presently, about 400 workers (each shift) are engaged in the washing section
comprising of both male and female workers.
Existing pollution control facilities: Factory operates an Effluent Treatment Plant with a capacity of 5
m3/hr of wastewater. Routine monitoring is done to maintain acceptable limit of discharged treated
wastewater quality. Solid wastes are sold to authorized buyers frequently. Presently, there is no control
on air pollution emissions.
Certifications: The factory has an updated environmental clearance certificate (ECC) from Department
of Environment (DoE), Government of Bangladesh. The product range has been certified against BSCI
which claims that textiles are free from harmful substances.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 13
1.2 CP Team
Factory CP Team:
In order to carry out the CP Assessment, a CP team was created at the factory level. The names of the
members are given below:
Name Designation Designated Role in CPA
Md. Meraj Uddin General Manager Team Leader
Shaikh Mohammad Bachu Manager, Admin & Compliance Asst. Team Leader
Mst Shahnur Akhter HR & Welfare Officer Compliance Co-ordinator
Md. Zahirul Islam Compliance Officer Compliance Co-ordinator
Md. Moniruzzaman Fire Safety Officer --
Md. Saiduzzaman Lab Incharge --
Md. Razu Electrical In-charge --
The factory’s CP team was very co-operative during the assessment. There are scopes for strengthening
the awareness among the core team members regarding the CP concept and its benefits. Sharing a
standard paper prior to and during assessment can be helpful to get them involved and committed. CP
core team can further disseminate the basic concepts and benefits across the factory staff.
Assessor CP Team:
The CP Assessment was carried out by following team.
Name Designation Designated Role in CPA
Shamsun Nahar Lucky Co-ordinator (Social) and Consultant OHS
& Wash Team Leader
Muhammd Fakhrul Alam Co-ordinator (Technical) All Technical Assessor
Md. Selim Reza Project Engineer (Electrical) Electrical Assessor
Md. Saifullah Project Engineer (Electrical) Utility Assessor
Nahid Akter Katha Project Engineer (Chemical) Process Assessor
Parthiban. V.S ASSIST India Junior Expert
J. Nages Kumar ASSIST India Senior Tech. Expert
Rey Macaro ASSIST/ECCI Senior Consultant (EHS)
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 14
2 Overview & Current Baselines
2.1 Description of production processes
Target Fine Wear Limited is washing unit of cotton, polyester/cotton blended fabric. The factory has
knit washing capacity of 25,000 pcs per day (from factory provided data). The factory also has a
knitting unit producing mainly cotton yarn. Cotton-Polyester blends are also processed in the factory.
Except wet process, the factory has also set up stitching units within the same premises.
The major production sequences are given in figure 1
Figure 1: Production process sequence
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 15
The washing process sequences are given in figure 2
Figure 2: washing Process sequence
Product range:
The major products include:
1. Polyester fabric
2. Wool
3. Acrylic
4. Nylon
5. Cotton fabric
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 16
Actual Production
The average yearly productions for Dec’14-Nov’15 are as follows:
Product type Yearly production Remarks
Sweaters 1,553 Tons cotton, polyester/cotton blended fabric
*Based on 300 days per year
** Avg. weight for per pc sweater is 0.221 kg
2.2 Main Inputs
2.2.1 Water
The source of water for the factory is ground water. Submersible pumps are used to extract water.
Source Average consumption/year (2015) Cost/year (2015), USD
Ground water 41,334 m3 7,950
*1 USD = BDT. 78.00 and Water cost: 15 BDT/m3 which includes water pumping & distribution cost,
treatment cost and effluent treatment cost.
Water baseline (KPI):
The water consumption KPI for the wet section has been calculated and presented below:
Product Average water consumption Average water cost/unit of
product, USD
Sweaters 27 litre/kg 0.005
Metering & water management:
Target Fine Wear Limited has installed water flow meters to measure the groundwater production,
washing process and ETP discharge volume. No water balance diagram has been established so far by
the factory. Values provided by the factory are used to determine the water consumption in the factory.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 17
Water balance diagram
A water balance diagram has been established based on flow meter readings, on-site assessment and
with the help of the factory CP team. The accuracy of the data is related to flow meter accuracy and
water consumption analysis for available process flow diagrams.
Figure 3 presents the water balance diagram.
Figure 3: Water Balance Diagram
As per provided factory information, all of the condensate water is being drained from the machines.
This water is going to sewage directly. The waste water from the washing section is treated in the
wastewater treatment plant and then discharged at the nearby river. An amount of water is evaporated
during drying process.
From the water balance diagram it can be said that majority of the water is consumed by the washing
section. Condensate is not returned to the boiler feed water tank.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 18
2.2.2 Energy
The factory is mainly dependent on national natural gas supply for running major equipment like boilers
and few process machineries and also dependent on national grid to meet the electrical power
requirement as a prime source of electricity. They have also a diesel generator to meet emergency
needs.
Fuel type Average consumption/Month Average Cost/Month, USD
Natural Gas 21,901 m3 2,064
Diesel 2,164 litre 1,887
Grid Power (REB) 107,735 KWh 10,414
*Combined power cost7.54BDT/kWh
Electrical energy baseline (KPI):
The electrical energy consumption KPI for the wet processing section has been calculated and presented
below:
Product type Average power consumption Average power cost/unit of
product, USD
Garments 0.832 kWh/kg 0.0809
Metering & power management:
Currently, they have one kWh meter across grid (REB) supply system centrally. No kWh meters are
available in the departmentally to measure specific power consumption and record the readings on
continual basis to calculate the specific energy consumption at user point.
Electrical energy balance diagram
The electrical energy balance diagram is established using the actual power generation data taken
during the assessment period and load balance data given by the factory.
Figure 4: presents the electrical energy balance diagram for the factory
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 19
Figure 4: Electrical Energy Balance Diagram
From the energy balance diagram, it is clear that productions units like knitting, linking and washing
sections are the major energy consumers.
Steam Baseline (KPI):
The steam consumption KPI for the wet section has been calculated and presented below:
Product Average steam consumption Average steam cost/kg of product, USD
Washed Garments 0.96 kg/kg 0.012
Since no metering was available, figures have been generated from basic calculation based on on-site
data and machine data.
Metering & Steam Management:
The steam demand is variable and there is no steam flow monitoring system installed to measure the
steam production and/or the amount of steam that was consumed by the various departments and
processes.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 20
Steam Energy Balance Diagram
No meter is available in the factory to measure the steam generation as well as steam consumption.
Steam balance diagram is established considering boiler capacity, running hour, feed water
consumption pattern and steam flow parameters at consumer ends.
Figure 6 presents the steam balance diagram created for the factory:
Figure 5: Steam balance diagram
From the steam balance diagram, it is clear that all the condensates are being drained.
2.2.3 Process Chemicals:
Chemicals for washing Average consumption/year Cost/year, USD
Silicon 4,326 kg 10,57,616
Softener 1,414 kg 3,18,150
Detergent 6,972 liter 1,39,440
Acetone 5,460 liter 6,52,488
*From Target management. (Filled in data are based on 2015 year)
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 21
2.3 Main Equipment
Process:
Almost all of the machines in washing section are relatively old. A dedicated Lab and sampling room is
set up beside the washing section.
Washing Section Machines:
Name of Equipment Origin Capacity Quantity
nos.
1 Flying Target Washing Machine China 68 03
2 Flying Target Dewater Machine China 100 02
3 Flying Target Drying Machine China 68 08
Utility:
Target Fine Wear Industries Ltd., using grid power from REB as a prime source of electricity to meet
the electrical power requirement and a Diesel Generator are used to meet the emergency power
requirements. They have 3 boilers and one compressor. All the boilers are gas fired. Air compressor is
mainly used for cleaning purpose like machine & human body cleaning. They have no condensate
recovery system.
# Equipment type Number of Machine Installed Capacity Unit
1 Boiler (Prime) 2 1.47 ton/hr
2 Boiler (standby) 1 470 Kg/hr
3 Diesel Generator 01 600 kVA
4 Air Compressor 01 5.5 KW
5 Submersible pump 02 4 KW
6 Booster pump 01 5.5 KW
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 22
2.4 Waste streams
During the assessment, wastewater parameters were checked and previous wastewater analysis reports
were collected from the factory. These are presented in the following tables.
Waste Stream Average
generation Remarks
Wastewater 47 m3 /day Wastewater is treated in ETP and then discharged
COD in discharged water 1 kg/day Considering ETP outlet water quality report
CO2 emission (GHG effect) 4.58 ton/day Direct CO2 emission factor 0.804 kg CO2/kWh
Indirect CO2 emission factor 0.67 kg CO2/kWh
Waste Stream Characterisation
During the assessment, wastewater parameters have been checked and also previous wastewater
analysis reports have been collected from the factory. These are presented in the following tables.
The report shown in the table below is done by an external agency; Bureau Veritas Consumer Products
Services (Bangladesh) Ltd. Target Fine Wear Industries Ltd. does not have an environmental clearance
certificate from DOE. The ETP test report from Bureau Veritas is shown below.
Factory provided report result (done by Bureau Veritas, on 09/09/2015):
Waste stream/
Parameters
TDS
(ppm)
TSS
(ppm) Conductivi
ty (µs) pH
Temp.
(0C)
COD
(mg/l)
BOD
(mg/l)
DO
(mg/l)
Outlet water
from ETP -
35 NAV
8.2 at
23 33 20 8 NAV
Country DOE
limiting values <2,100
**NS 6.0-9.0 **NS <200 <50
4.5-
8.0
On site measurement (on 27/12/2015):
Waste stream/
Parameters TDS (ppm)
Conductivity
(µs) pH Temperature (0C)
Outlet water from ETP 390 780 7.8 22
Country DOE limiting
values <2,100 **NS 6.0-9.0 **NS
**NS: Not specified
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 23
2.5 Water Footprint
Factory uses groundwater to meet all its processing needs. Wastewaters generated are being discharged
to after treatment in the ETP.
Water Footprint values have been calculated based on available data. Following table shows the values
of various Blue and Grey water footprint of the factory.
Blue water footprint:
Parameter m3/year m3/kg of product
Blue water footprint for the factory 41,334 0.027
Blue water footprint for washing 15,344 0.01
Post data source: Factory provided information
Grey water footprint:
Parameter m3/year
Grey water footprint for TDS 1,964
Grey water footprint for BOD 2,212
Post data source: ETP flow meter and external test results
2.6 Water Sanitation & Hygiene (WASH)
Overall drinking water supply system:
Source of the drinking water (includes source and type): The source of drinking water is mainly
underground water which is pumped out by submergible pump (300ft-400ft) that goes directly to a
water tank at the roof through a PVC pipe.
The main resource is the ground water and the water is extracted using deep tube wells. The water is
pumped to different processing areas including Washing, household, boiler and generator cooling
water. Drinking water supply adequate & quality acceptable.
Water treatment of drinking water (filtration, cooling): Cartridge filter is used for water filtration
and being cooled inside the filter for drinking purpose. The filters are regularly checked and cleaned
at least once in a month.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 24
Water quality: Drinking water quality has been tested half yearly. The updated (15.10.2015) test
report is available and the water parameters are within the acceptable limits. Icddr,b is the testing
authority.
Drinking water management (frequency of drinking): In Summer, drinking water frequency is
6-7 times per worker in a day; however, the frequency is 3-4 times per worker/day in winter. There
are 36 drinking water points (each floor three drinking water point (DWPs)) for the worker in the
factory.
Responsibility for proper functioning: Shaikh Md. Batchu, Manager, HR and Compliance, has
been assigned for maintaining the drinking water facilities of the factory.
Employee vs. drinking water point: The total number of workers in the factory is 1800 presently,
at wet process the ratio is 1:50.
Sanitation Facility: The total number of toilet is 88 in the factory, whereas, 40 toilets are for the
male and the rest of the 48 toilets belong to female workers. The factory has no urinals. Currently,
the toilet number and worker ratio is 1:20. For the first 100 male workers, the toilet-worker ratio is
1:25 and it is 1:31 for the rest of the male workers in the factory. For the female workers the toilet-
worker ratio is 1:9.38 in the factory. According to regulatory rules, that ratio should be 1:25 for the
first 100 male workers. The ratio goes up to 1:50 for above 100 male workers. According to the
labor law of Bangladesh, the toilet-worker ratio for the female is 1:25.
Existing sanitation facilities:
Availability of soap in toilets: The soaps are not available in all toilet and hand washing point for
the workers. Availability of water and soap for hand washing and sanitation facilities is hourly
monitored with checklist. Md. Zahirul Islam, Compliance Officer, has been responsible for ensuring
cleanliness of sanitation facilities within the factory.
Responsibility for sanitation: For ensuring proper functioning of the sanitation facilities, a
responsible person is available on the factory. Md. Zahirul Islam, Compliance Officer, has been
responsible for ensuring proper functioning of the sanitation facilities.
Awareness and training programmes on basic hygienic behaviours and Practice: The training
takes place once in every month. Approximately, 25-30 workers participate in the training.
Documents are available in the factory.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 25
2.7 Occupational Health & Safety (OHS)
The factory has established an operating structure to manage occupational health and safety (OHS)
issues. The existing conditions of OHS are described below:
Existing Condition of Occupational Health & Safety (OHS):
Occupational Health & Safety (OHS) Policy: An Occupational Health and Safety (OHS) policy
and programs exist in the factory Shaikh Mohammad Bachu, Manager, HR & Compliance, is in
charge of Environmental Health and Safety department.
Trainings on OHS:
An emergency response team (fire team & first aid team) has been established in the factory.
Training is provided concerning health & safety and environmental issues (First aid, fire fighting,
health safety, PPE, Machine Safety Training, chemical handling and storage of dangerous
substances) in the factory.
The training takes place once in every month. Approximately, 25-30 workers participate in the
training.
Mock emergency drills been organized once in a month for fire safety purpose.
Personal Protective Equipments (PPEs) usage:
Workers are not using PPE regularly in washing area, chemical store and boiler room.
Use of PPE is not regularly checked by supervisors
Majority of the workers at the washing areas are not aware about PPEs.
Chemical Safety:
The room is smell and no sufficient shelf is available. So they put on the floor.
Chemical store is untidy and softeners are found spread over the floor. Bad housekeeping.
There are kept on others material in the chemical room.
PPE was found very inadequate. Proper storing and labelling were absent.
Written procedure for spillage and Spillage kits are not available in the Chemical storage.
Fume hood and eye wash basin are not build in the Chemical Store.
The in charge of chemical store is not aware of RSL and banned chemicals.
Chemical Inventory
The factory is aware of the banned chemicals and requires compliance statements from their
suppliers in order to avoid unintentional use. An inspection of the chemical storage and available
MSDS did not reveal any banned chemicals as they mainly use Detergent and Softener. MSDS are
available for most of the chemicals.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 26
Fire Safety & Emergency Conditions:
Fire extinguishers were adequate in the production and utility areas. These fire extinguishers are
checked and maintained monthly basis by the factory.
During the assessment, access to a few fire extinguishers was obstructed by garments and other
materials. There may be more instances when access to fire extinguishers may be blocked due to
production load.
The evacuation maps are posted visibly in all workshops.
Three emergency exits in the factory and fire Hoses points is available
All Fire fighting equipments, fire alarm & prevention system are exists in Company but Smoke
detector was not automatic.
First Aid:
The number of workers trained in first aid measures is sufficient. Total number of workers
trained as first aiders is 30. They have 2 first aid boxes in each floor.
Medical care is free of charge and first aid facilities sufficient. Full time doctor, Nurses and child
care facilities are available in the factory premises.
Noise Management:
The noise level has not been measured by the factory and high noisy areas have not been
identified as such Genaretor, boiler and compressor room are regarded as very high noise area.
Noise monitoring at different section of Target was conducted during the CP assessment. The
noise monitoring results indicate that the noise levels at two monitored areas exceed the safe
noise exposure limit of 85 dB. Table below present location and intensity exceeding safe noise
limits:
Table: Noise Level Measurement
S. No. Units Noise Levels dB
1 Boiler room 90- 91
2 Compressor room 92-95
Solid Waste Management:
Department wise recording of solid waste generation is not done therefore no data was made
available by the factory.
The major portion of solid waste generated includes jutes, cut piece garments, electrical wast,
ETP sludge, chemical drums and empty cartons.
There is no earmarked storage space of Solid waste in the factory. Solid waste is collected and
kept in the ETP Building in the factory premises
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 27
After 15 days waste is sold out to the respective agents but weekly /monthly recording of solid
waste generation is not done by the factory.
Hazardous & non-hazardous items such as oil filter from generator or used electric tube lights
that is generated but not segregated.
The team did not observe any recycling activity.
There are some observations on housekeeping by CP Assessment Team of BCAS for
“Occupational Health & Safety (OHS)” are given below:
Adequate space is provided around and between all equipment. However, the working area is not
clean and orderly enough.
Material storage on walkway and backside of machines found at some places of wet processing
zone.
Now, factory managements have a system of registering accidents and to some extent, general
awareness programs been taken.
2.8 Environmental Management System (EMS)
The factory has an environmental policy in place. Responsibilities and authorities for environmental
management have been defined and documented. On the contrary, procedure has been established to
identify the environmental aspects of its current and relevant past activities. Corrective Action Plan
(CAP) takes place once in every month conducted by HR and Compliance department under the
supervision of Manager, HR and Compliance.
The factory has renewed the environmental clearance certificate from Department of Environment
(DOE), Bangladesh. An operational ETP treats the wastewaters generated in the factory before
discharging. However, the ETP is not enough for the now increased production. The cooling waters are
being drained in the factory and it is going to the sewerage line instead of ETP. A small chemical ETP
of 5 m3/hr capacity is running. The wastewater analysis report prepared by the factory has been
collected. The wastewater parameters have been tested by the CP team by BCAS and the result shows
that the parameters have been kept under controlled.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 28
3 Assessment and CP options
3.1 Opportunities in process areas
Option 1: Calibration of different gauges and meters utilized in processing area
Observation: During on-site assessment, it was observed that some of the temperature gauges were not
working efficiently. And calibration of gauges is not carried out regularly.
Description of option Technical feasibility Environmental
feasibility Economic feasibility
It is recommended that
a full calibration plan be
implemented. All
gauges (temperature and
pressure) must be
properly calibrated
according to the
prescribed calibration
plan at specified
intervals.
● Minimum process
change
● Training required
● No impact ● Minor investment.
Investment depends
on no of gauges.
● No direct economic
benefit but improves
safety
Option 2: Installation of level indicator in the washing machines
Observation: No water level indicators were found in the washing machines. As a result, wastage of
water was observed during the assessment.
Description of option Technical feasibility Environmental
feasibility Economic feasibility
It is recommended that
every washing machine
should have a water
level indicator so that
correct usage of water
can be maintained.
● Minimum process
change
● Training required
● Reduction of
wastage of water
● Estimated
Investment: 100
USD
● No direct
economic benefit
but reduces water
usage.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 29
Option 3: Optimization of dryer time in washing section
Observation: It was observed that the drying time for all products is 30 minutes to one hour. During the
assessment, samples were measured at various stages and it was evaluated that most of the time the
products are bone dried and later on the products pick up moisture from the atmosphere.
Description of option Technical
feasibility
Environmental
feasibility Economic feasibility
The drying time can be adjusted to
reach a minimum of 5% moisture
content.
This adjustment can be set by
sampling and establishing moisture
content versus time plot for
individual samples.
Proven
technology
Minimum
process change
Training
required
NG savings:
3,740 Nm3/year
possible
GHG
reduction: 7.1
ton/year
Investment: 500 USD
Savings: 290 USD
Payback: 21 months.
Option 4: Monitoring liquor ratio for washing
Observation: From the factory provided data, it was observed that the liquor ratio varies from 1:11 to
1:18.
Description of option Technical
feasibility
Environmental
feasibility Economic feasibility
It is recommended that a constant
liquor ratio (1:8) should be
maintained during washing process.
This helps in avoiding the
unnecessary use of water.
Proven
technology
Minimum
process change
Training
required
Water savings:
7,765 m3/year
Power saving:
15,448
kWh/year
GHG emission
reduction:
10.35 tons/year
Investment: None
Annual saving: 1,493
USD
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 30
Option 5: Reusing the discharged water from hydro-extractor
Observation: The discharged water from the hydro-extractor is been dumped into the ETP though it can
be reused.
Description of option Technical
feasibility
Environmental
feasibility
Economic
feasibility
It is recommended that the water from
the hydro-extractor should be stored
and use it in other factory operations
like floor washing, car washing, etc.
Minimum
process change
Water saving:
3,232 m3/year
Power
saving:4,286
kW/year
GHG emission
saving: 2.87
Tons/year
Estimated
investment:
500 USD
Annual
saving: 622
USD
Payback: 10
months
Option 6: Promoting the concept of “zero discharge”
Observation: The on-site assessment of discharge water from ETP shows that the factory can achieve
the target of “zero discharge” with minimum investment.
Description of option Technical
feasibility
Environmental
feasibility
Economic
feasibility
It is recommended for the factory to re-
use at least 90% of its discharge water
for washing and sanitation purpose.
The discharge water needs to be treated
before re-use.
Minimum
process change
WTP
installation
required
Acceptance of
the concept
needed
Water saving:
12,748 m3/year
Power saving:
16,907 kW/year
GHG emission
saving:11.33
Tons/year
Investment:
Needs to be
estimated
Annual
saving: long
Payback:
Long term
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 31
3.2 Opportunities in utility area:
Option 1: Installation of energy efficient lights
Observation: T8-52W tube lights with magnetic ballast are being used. The total numbers of T8 tube
lights were found to be1800pcs.
Description of option Technical feasibility Environmental
feasibility Economic feasibility
It is recommended to
replace traditional T8-
40W tube lights with
T5-24W, which is more
efficient and energy
saving and also higher
intensity light output
than T8.
Known technology
and available
materials.
No expertise
required.
Power saving:
181,440kWh/
year
GHG
emission
reduction
121.56tons/ye
ar
Estimated
investment: 23,077
USD
Annual saving:
17,539 USD
Payback: 16 months
Option 2: Installation of energy efficient motor
Observation: It is observed that most of installed motors are typical old type. These old motor can be
replaced by efficient motor.
Description of option Technical feasibility Environmental
feasibility
Economic
feasibility
It is recommended to replace
typical old motor by IE2 type
efficiency class motor which is
more energy efficient. No
immediate corrective action is
required. It is recommended for
future, whenever a motor is
replaced, it should be replaced
with energy efficient class (IE2
class). It will also give energy
savings.
Known
technology and
available
materials.
Power saving:
3,352kWh/year
GHG emission
reduction
2.25tons/year
Estimated
investment:
577USD
Annual saving:
324 USD
Payback: 21
months
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 32
Option 3: Installation of Servo Voltage Stabilizer on lighting load Circuit
Observation: It is observed that voltage supplied often on a higher side leading to higher energy
consumption for lighting.
Description of option Technical
feasibility
Environmental
feasibility
Economic
feasibility
It is recommended that servo
voltage stabilizer be installed to the
lighting load circuit. Installation of
SVS on that lighting load will give
good energy savings through
maintenance of optimum voltage
(200V) & lifetime; This will also
reduce regular maintenance costs.
Known
technology
and available
materials.
Power saving:
83,841kWh/year
GHG emission
reduction:
56tons/year
Estimated
investment:
11,026 USD
Annual saving:
8,105 USD
Payback: 16
months
Option 4: Installation of energy meters to monitor specific energy consumption
Observation: The specific energy consumption of individual sections could not be calculated directly
because they are using one energy meters centrally provided by REB to measure the total power.
Specific power consumption (kWh/kg) is an important parameter to evaluate the performance and
efficiency of the specific machine or specific section like washing, knitting, linking & swing finishing
sections.
Description of option Technical
feasibility
Environmental
feasibility Economic feasibility
It is recommended to install energy
meter gradually at different sections
like washing, knitting, linking &
swing finishing sections to measure
specific power consumption and
record the readings on continual
basis to calculate the specific energy
consumption.
Meters
available
Measuring
consumption will
automatically lead
to an improved
awareness and a
strengthened
resource
management.
No straight forward
payback but will help to
set benchmarks, ensure
proper monitoring to
identify unexpected
resource usage and need
for necessary corrective
action immediately.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 33
Option 5: Proactive Maintenance of Electrical Systems
Observation: Target Fine Wear Industries Ltd., has followed reactive maintenance but proactive and
preventive maintenance is very important for electrical sections. Electrical safety is one of the
paramount importance to prevent electrical fire hazards.
Description of option Technical feasibility Environmental
feasibility Economic feasibility
It is recommended to follow
proactive maintenance schedule
to prevent unwanted shutdown of
machines and to prevent electrical
fire hazard in the factory.
Well-known
concept
None
Estimated
investment: No cost
involvement
Annual saving: No
direct Saving
Payback: N/A
Option 6: Installation of condensate recovery system
Observation: Condensate from steam dryers and steam irons are pure in quality and this should be
returned to the boiler feed water tank to raise its temperature. Currently, the plant drains out all the
condensate from process section. Throughout the assessment boiler feed water temperature was found
at 25 °C which is very low for boiler feed water. For every 6 °C rise in boiler feed water temperature
boiler efficiency increases by 1%.
Description of option Technical feasibility Environmental
feasibility Economic feasibility
By recovering all the
condensate and flash steam
installing a closed loop or
pressurised condensate
recovery system, the feed
water temperature can be
increased up to 80 °C. As a
result boiler overall
efficiency will also
increase upto 10%.
Proven
technology
Minimum
process
change
NG savings:
26,281
m3/year
GHG emission
reduction:
50ton/year
Estimated
investments:
2,000 USD
Estimated
savings : 2,494
USD
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 34
Option 7: Minimizing Heat Loss by proper insulation of bare surface, pipes, valves and correction
of steam leakages and traps.
Observation: It has been observed that significant amount of steam pipes and valves are un-insulated.
Also steam leakages and faulty steam trap are found at multiple points. The boiler feed tank size seems
to be very small as compared with boiler size. Feed tank size should be matched so that all the
condensate can be collected in the feed tank. The feed tank and condensate return line should be also
insulated so that heat radiation can be minimized.
Description of option Technical feasibility Environmental
feasibility Economic feasibility
Proper insulation of all un-
insulated steam line
(approx. 130 feet), steam
valves (27 nos.), feedtank,
repair of steam leakage &
steam traps will ensure
steam loss saving of
around 4 ton/year.
Known
technology and
available materials
NG saving:
39,136Nm3/year
GHG emission
reduction: 73.9
ton/year
Estimated
investment: 2,520
USD
Annual saving:
8,315 USD
Payback:2 months
Additional potential saving opportunities:
From the stack analysis of boiler, it was found that excess air % is imbalanced (1.9%) whereas
the optimum excess air % should be at a range of 15-20%.This low excess air % indicates the
incomplete combustion or the presence of high quantity carbon mono oxide in stack, which will
create soot in the chimney (fire section) and reduce the heat transfer from combustion to water
side. Burner analysis and tuning should be carried out at all the firing modes and cleaning of the
boiler heating surface is required at regular intervals depending on stack analysis results.
Presently, manual blow down is in practice and from various reports it is found that the blow
down water parameters is variable. So, it would be an effective step to keep TDS meter at site
to evaluate effective blow down frequency and time with respect to TDS value. This way,
unnecessary heat loss can be avoided.
Water quality parameters are not tested for boiler feed water. Hardness was tested and the value
was found 147 ppm which is higher than the safe limits. Feed water hardness should be
maintained below 10 ppm to control scale deposition. This will help lower maintenance, water
and chemical costs.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 35
3.3 Opportunities in Water Sanitation & Hygiene (WASH)
Suggestions for Drinking & sanitation Water Facilities Supply System:
Factory management arranges awareness sessions to improve the hygiene practices of workers in a
healthy environment.
# Description of option Investment
Category Environment Impact
1 Ensure drinking water quality and testing
frequency as per regulatory standard
Minor Regulatory Compliance
2 Ensure sufficient drinking water points according
to the ratio of workers
Minor Regulatory Compliance
3 Ensure cleanliness of toilets, sanitation facilities
and availability of hand wash materials at toilets Minor Ensure healthy and
hygienic environment
4 Ensure showers and washing rooms for workers Minor Ensure healthy and
hygienic environment
3.4 Opportunities in Occupational Health & Safety (OHS)
From the assessment, following few areas have been identified where an improvement can enhance the
safety standards:
# Description of option Investment
Category
Environment
Impact
1 Improve housekeeping Minor Ensure safe working
environment
2 Strengthen the accident investigation procedure Minor Ensure safe working
environment
3 A monitoring system could be in place to make sure the
usage of PPE. Minor Ensure safe working
environment
4 Sufficient Fire Fighting Equipments (FFEs) could be in
place in all areas to cope up with the accidents.
Minor Ensure safe working
environment
5
Briefing sessions and training programs could be
arranged for the associated workforce on electrical
hazards, their consequences, safe practices and
corresponding mitigation actions
Minor Ensure awareness for
safe working
environment
6
A housekeeping check sheet and periodic monitoring
program specially for the DB boards could be developed
and used to create a sustainable system
Minor Ensure safe working
environment
7
Note: Relevant checklist is shown in the Annex
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 36
3.5 Opportunities in Chemical Inventory
# Description of option Investment
Category Environment Impact
1 Improve labelling and MSDS display Minor Ensure safe chemical
handling
2 User friendly eye wash and shower with continuous
water supply facility needs to be ensured
Minor Ensure safe working
environment
3
Training of the workers in the chemical stores should
be conducted routinely. This training, amongst other,
should include the topics on chemical handling; spill
control procedure and chemical store management.
Minor Ensure safe working
environment
4 Spilled materials and liquids should be cleaned up
immediately.
Minor Ensure safe working
environment
5 Sufficient toolkit for clean up the spilled chemicals
could be provided.
Minor Ensure safe working
environment
6 Restricted Substances List (RSL) could be displayed in
the main chemical store as well as sub-store.
Minor Ensure safe working
environment
3.6 Solid Waste Management System
Description of option
Investment
Category
Environment Impact
A proper solid waste management system is suggested
for the factory that should comprise Minor Ensure safe working
environment
A Solid Waste Inventory to keep record and track of
the generation and disposal of solid waste.
Minor Ensure safe working
environment
Segregation of waste on the basis of type and
department.
Minor Ensure safe working
environment
Waste minimization efforts based on the monitoring
and analysis of segregated waste.
Recycle/ reuse options after waste minimization efforts
may be explored.
Minor Ensure safe working
environment
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 37
3.7 Opportunities in Environmental Management System (EMS)
The factory has established a simplified environmental policy and procedure. General awareness
programs are organized for the workforce on water use reduction and waste management. A procedure
should be established to identify the environmental aspects of its current and relevant past activities.
# Description of option Investment
Category Environment Impact
1
Establish specific environmental policy and
procedures
Minor Ensure environmental
awareness and regulatory
compliance
2
SMART environmental objectives and targets
could be established and documented at each
relevant function and level in the factory
Minor Ensure environmental
awareness and compliance
3 Proper labelling waste and segregation of waste Minor Ensure environmental
awareness and compliance
4 Waste management procedures’ development and
training
Minor Ensure environmental
awareness and compliance
5 Establish a procedure to identify the
environmental aspects.
Minor Ensure environmental
awareness and compliance
6
Reuse of ETP water could be a significant
improvement creating zero discharge system in the
factory.
Major Ensure 3R Principal and
regulatory compliance
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 38
4 Conclusion
4.1 Impact Summary of Measures Recommended
Total 13 options have been identified of which 6 is applicable in the wet processing section and 7 in the
utility section. A summary is given in the table below:
Area Total number
of options
Estimated
investment,*USD
Economic
benefits,
USD/year
Environmental benefits/year
Process 6 1,100 2,405
Water saving: 10,997 m3
Power Saving: 19,734 kWh
NG saving: 3,740 Nm3
GHG reduction: 31.65 tons
Utility 7 39,200 36,777
Power saving: 268,633 Nm3
NG saving: 65,417 Nm3
GHG emission reduction
303.7 tons
Total 13 40,300 39,182
Water Saving: 10,997 m3
NG saving: 69,157 Nm3
Power Saving: 288,367
kWh
GHG emission:335.35 tons
*1 USD: BDT. 78.00
The total amount of savings calculated is 39,182 USD. The savings are based on the reduction in costs
of water, steam, natural gas and electricity usage. The total estimated investment to realize all the
recommended benefits is USD 40,300 with an estimated payback period of about 12.3 months.
CP Assessment Report Target Fine Wear Industries Ltd
Promoting CP in the Textile Washing/Dyeing/Finishing Sector in Bangladesh 39
4.2 Impact Measures on Savings (Percentage Reduction)
The main objective of the CPA is to assess Water, Energy, Chemicals, Occupational Health & Safety
(OHS), WASH, Water Footprint and the Environmental Management System (EMS). The table
described below gives a qualitative assessment in the above mentioned major four areas. The general
assessment of the industrial set up is given in the centre. The factory team and the senior management
were found to be very cooperative and have supplied the required data to the best of their abilities..
The resource savings compared to the consumption is shown in the table below:
Resource/impact Annual savings Annual consumption/generations
Water, m3 10,997 30,337 (27% reduction)
NG, m3 69,157 193,654 (26% reduction)
Power, kWh 288,367 1,004,448 (22% reduction)
GHG, ton CO2e 323.8 1,038.8 (23.7% reduction)
CP Assessment Report Target Fine Wear Industries Ltd
5 Annex
CP Assessment Report Target Fine Wear Industries Ltd
Unit Name Target Fine Wear Industries Ltd.
Type of Industry Sweater Washing
Average production 113 Ton (Monthly)
Assessment delivery date 21 July 2016
Implemented Measures As of August 2016
Implemented Cleaner Production Measures
S.
No. Recommendation Comments
%
Implemented
Investment
(BDT)
Yearly
Financial
Savings
(BDT)
Resource Saving
Water
Saving
(m3 per
year)
Electricity
Saving per
year
(kWh/yr)
NG Saving
(m3 per year)
Steam
Saving kg
per year
GHG Avoided
in tons
(CO2e) per
year
1
Calibration of different
gauges and meters utilized
in processing area.
A register book is prepared for
monitoring the calibration. 100 0 0 0 0 0 0 0
2
Installation of level
indicator in the washing
machines
They cannot install water level
scale for individual machine,
but use a common scale for
measuring water.
0 0 0 0 0 0 0 0
3 Optimization of dryer time
in washing section Implemented 100 0 0 0 0 0 0 0
4 Monitoring liquor ratio for
washing
they reduce liquor ratio from
1:13.8 to 1:11 80 0 26,208 1,764 3,509 0 0 2.3
Target Fine Wear Ind.
Ltd
CP Assessment Report Target Fine Wear Industries Ltd
S.
No. Recommendation Comments
%
Implemented
Investment
(BDT)
Yearly
Financial
Savings
(BDT)
Resource Saving
Water
Saving
(m3 per
year)
Electricity
Saving per
year
(kWh/yr)
NG Saving
(m3 per year)
Steam
Saving kg
per year
GHG Avoided
in tons
(CO2e) per
year
5 Reusing the discharged
water from hydro-extractor Not Accepted 0 0 0 0 0 0 0 0
6
Promoting the concept of
“zero discharge
3rd party is involved in the re-
construction of their ETP. The
concept will be discussed with
the 3rd party.
100 0 0 0 0 0 0 0
7 Installation of energy
efficient lights
900 pcs LED lights were
installed. 100 463,944 805,896 0 106,836 0 0 71.6
8
Installation of energy
efficient motor
Log book prepared for
recording the re winding times
of motor. In future if motor
replace, it will be replace by
efficient class motor.
0 0 0 0 0 0 0 0
9
Installation of Servo
Voltage Stabilizer on
lighting load Circuit
Not possible in these project
period, have consideration for
future.
0 0 0 0 0 0 0 0
10
Installation of energy
meters to monitor specific
energy consumption
Not Accepted 0 0 0 0 0 0 0 0
11 Proactive Maintenance of
Electrical Systems Implemented 100 0 0 0 0 0 0 0
12 Installation of condensate
recovery system They contact with third party. 50 0 0 0 0 0 0 0
CP Assessment Report Target Fine Wear Industries Ltd
S.
No. Recommendation Comments
%
Implemented
Investment
(BDT)
Yearly
Financial
Savings
(BDT)
Resource Saving
Water
Saving
(m3 per
year)
Electricity
Saving per
year
(kWh/yr)
NG Saving
(m3 per year)
Steam
Saving kg
per year
GHG Avoided
in tons
(CO2e) per
year
13
Minimizing Heat Loss by
proper insulation of bare
surface, pipes, valves and
correction of steam leakages
and traps.
For 497 ft hot bare pipe,
insulation is done. Insulation
material is Glass-wool. 1 inch
steam trap has repaired.
6 steam leakage in boiler steam
pipe was repaired.
100 110,760 756,288 0 0 66,000 763,000 124.7
Total Resources 1,764 110,345 66,000 763,000 199
Total BDT 574,704 1,588,392
Total USD $ 7,368 $ 20,364
Recommended=13
Agreed= 11
Implemented=9
OHS, chemical inventory, EMS, Wash
Options implemented, cost and possible savings
Options Recommended & Agreed (nos.) Implemented (nos.) Benefits (can also be qualitative) Remarks (why not or only partially implemented)
OHS 2 2 No financial benefits
EMS 3 1 No financial benefits Not prioritized
WASH 2 2 No financial benefits
CP Assessment Report Target Fine Wear Industries Ltd
Water footprint
Parameter Before (m3/day) After (m3/day) Reduction (%) Remarks (why not or only partially implemented)
Blue water footprint 138 137 0.72
KPI’s
Parameter Before After Reduction (%) Comments
Ground Water ( l/kg) 26.62 26.48 0.54 Ground water consumption/unit fabric production
Process Water ( l/kg) 12.77 10.33 19.10 Process water consumption/unit fabric production
Gas (m3/ton) 169 239 - Total NG consumption/Total fabric production
Electricity (MWh/ton) 0.83 0.78 5.96 Total steam consumption(process and Utility)
/Total fabric production
Steam (ton/ton) 1.98 2.78 - Total power consumption/Total fabric production
CP Assessment Report Target Fine Wear Industries Ltd
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