CLEANER PRODUCTIONPresent & Future

in DBL Group

About us

DBL Group is among the largestvertically integrated knit garmentsmanufacturing and exporting industryin Bangladesh. It has facilities for:

cotton spinning, fabric-knitting-dyeing-printing-

finishing and garments-cutting-sewing-printing-

washing-finishing.

Export destination

42 countries in 5 continents

Europe, 39%

Asia, 26%

North America, 21%

South America, 12%

Africa, 2%

Buyers

H&M Walmart-George Puma Esprit G-Star Decathlon VF Asia

FABRIC DYEING & FINISHING

Dye House

Mymun Textiles Ltd. – 2002Hamza Textiles Ltd. – 2006

Process: Dyeing & Finishing of knit fabrics

Total capacity: 40,000 Kg per day

Utilities

2 Gas based Generators, Waukesha-USA – 2,300 kWh

1 Standby Diesel Generator, Caterpillar-USA – 1,056 kWh

2 Gas fired Boilers, Cochran-UK – 19,050 kg/hr steam

Water Treatment Plant – 265 m3/hr

Effluent Treatment Plant (Biological) – 4,000 m3/day

Resource Total

Gas (M3) 8,717,792

Electricity (kWh) 10,042,902

Water (M3) 1,295,597

Steam (Kg) 58,941,132

Compressed Air (M3)

11,550,000

Dyes & Chemicals(Kg)

5,431,919

Resource Consumed - 2010

Status of Low Hanging and Medium Hanging Fruits - NRDC

DBL StatusSubject Best

PracticeYes No N/A

Water 7 4 3 -Energy 11 7 4 -Products & Chemicals

6 4 1 1

Transversal Issues

5 3 1 1

Total 29 18 9 2Percentage 62% 31% 7%

Process Improvement having impact on Water & Energy

Minimize washing and rinsing operations

DBL is using 3 effective rinses While average industry practice is 4-5 washes/rinses.

The water used per rinse by DBL is 6 ltr/kg while average industry practice is 21 ltr/kg.

WATER

Water ratio For DBL water ratio is 1:6 while for average industry it is 1:8. We are using SCLAVOS dyeing machines which combines the advantages of airflow and jet processes.

WATER

WATER

Use of Water Trigger Nozzles

For preventing water wastage in washing of process vessels, machines, chemical drums, floors, etc.

Utilization of Humidity Analyzer inside Continuous Dryer & Stenter

Fig: PLEVA Humidity Analyzer

PLEVA humidity analyzer is used

in stenters and driers

ENERGY

Moisture Controller atStenter & Dryer

Used in driers & stenters

Has sensors to determine themoisture content of fabrics andtemperature required to dry thefabrics.

Thus optimum use of gas andelectricity is ensured. Fig: PLEVA Moisture Controller

ENERGY

ENERGY

Dyeing process time of average todark color has been reduced to 6 to 8hours per batch which was previouslybetween 9 to 10 hours

Use of magnetic device for water softening

Cost of the “Eneflow” Magnetdevice is TK 150,000.

Scaling reduction 0.5 mm/yearcan save TK 300,000/year.

Payback period - 6 months only.

ENERGY

ParameterBefore

ENEFLOW (ppm)

After ENEFLOW

(ppm)Performance

TDS 101.5 96.5 5% TDS removed

Hardness 2.175 1.875 13% Hardness removed

PH 6.7675 7.015 PH Neutral

ENERGY

Water Hardness Removal

Automatic boiler blow down mechanism

DBL has automatic blow down system in boilerwhen TDS reaches above 2,700 mg/l.

This procedure contributes to increased boilerefficiency.

ENERGY

Use of air Nozzles Placed at compressed

air pipe line.

1 hour load on compressor has been reduced.

Figure: Air guns

ENERGY

Insulation & Leak-Repair

Insulation: Steam line

Leakage monitoring: steamtraps, steam line, compressed airline, water line

Thus energy & water loss isreduced.

ENERGY

Production & Resource Consumption 2010-11

Production and Consumption

PeriodFabric

Production - kg Gas m3 Electricity kWh Water m3 Steam Kg

2010 Jan - Dec 10,763,974.30 8,717,792.00 10,042,902.00 1,295,597.00 58,941,132.88

2011 Jan - Mar 2,565,371.49 2,027,220.00 2,030,331.00 245,003.40 13,326,458.91

Comparison 2010-11

Production and Consumption Comparison 2010 & 2011

Period Production Gas m3 Electricity kWh Water m3 Steam Kg

2010Monthly Average 896,997.86 726,482.67 836,908.50 107,966.42 4,911,761.07

2011Monthly Average 855,123.83 675,740.00 676,777.00 81,667.80 4,442,152.97

Environmental Benefit

Resource Consumption Comparison 2010 & 2011

Gas m3Electricity

kWh Water m3 Steam Kg

2010Per kg of

fabric 0.81 0.93 0.12 5.48

2011Per kg of

fabric 0.79 0.79 0.10 5.19 Change

Percentage 2.43% 15.17% 20.65% 5.13%

NoteWater & Steam consumption calculation is based on machine capacity in the absence of meters.

CO2 Emission Reduction

CO2 Emission per kg of fabric

Source UnitJan-Dec

2010Jan-Mar

2011Emission

ReductionReduction

%

Gas Kg 1.832 1.750 0.075 4.10%

Electricity Kg 0.093 0.080 0.013 14.08%

Resource Unit

Savings per kg of

fabricYearly

savings Cost/unit in (BDT)

Yearly Savings in

BDT

Yearly Savings in

USD

Gas M3 0.02 211,833 3.75 794,375 11,033

Electricity kWh 0.14 1,523,890 2.50 3,809,725 52,913

Total 4,604,100 63,946

Financial Savings

Fabric Production in 2010 : 10,763,974 kg

Savings will be around USD 175,000/year if savings of water, steam and compressed air is also taken into account.

Future Plan for Cleaner Production

A new project “Color City Limited” is under

construction. This project has capacity for 60,000

kg/day of fabric dyeing and finishing. The following

energy saving options are being included…….

• Energy Conservation in Washing and Rinsing• Recovery of Overflow Water at Stenter• Reuse of Spent Bath of Bleaching and its Washing• Heat Recovery from Stenter• Heat Recovery from Generators• Use of Electronic Ballasts instead of magnetic ballasts• Energy Efficient Lighting System• Use co-generation plants• Recovery of sodium sulfate• Installation of water, steam & gas flow meter.

Future Plan for Cleaner Production

Four member team has been formed foroptimizing energy and water usage.

Reduce carbon dioxide emission by 15% in thenext 3 years.

Benchmark and regulate energy consumption. Reduce diesel consumption in stand-by generators

by 10%. Train employees on energy and environmental

aspects within the industry.

Energy Management Centre

Thank You