Energy Efficiency in the Clothing Industry
Experience from the garment industry
Bertram Rollmann
PIRIN-TEX EOOD
Energy Efficiency Conference, Budapest, 12.05.2016
First of all….
some facts about the Bulgarian textile & clothing industry
T&C industry in Bulgaria
• 103 thsd. employees in the T&C industry 88% Clothing 12% Textiles
• Major employer in the country –21% of the employees in the manufacturing industry;
• Over 5000 registered companies, 4400 of which in the clothing subsector;
Energy Efficiency Conference, Budapest, 12.05.2016
• Steady post-crisis growth in exports – 1,9 billion EUR in 2015 75% Clothing
25% Textiles
• T&C exports account for 8,2% of the total Bulgarian exports
0
200 000
400 000
600 000
800 000
1 000 000
1 200 000
1 400 000
1 600 000
1 800 000
2 000 000
2006 г. 2007 г. 2008 г. 2009 г. 2010 г. 2011 г. 2012 г. 2013 г. 2014 г. 2015 г.
thsd. Euros Bulgaria’s T&C exports 2006-2015
T&C industry in Bulgaria
Energy Efficiency Conference, Budapest, 12.05.2016
Major export partners (2015)
Germany 22,0%
Italy 19,9%
Greece 10,2%
France 9,8%
UK
5,3%
Spain3,9% Romania 3,3%
Belgium 3,0%
Turkey 2,6%
Netherlands 2,5%
Austria 2,1%
Poland
1,6%
USA 1,1%Sweden 1,1%
Switzerland 1,0%
Denmark 0,9%
Macedonia 0,8%
Croatia 0,7%
Czech rep. 0,6%
Russia 0,5%
Others 7,0%
Rest of the world
15,5%
90% of the T&C exports are for the EU market
T&C industry in Bulgaria
Energy Efficiency Conference, Budapest, 12.05.2016
633 635 631640
666 671681 682
473490 494
505 510
538547
566
400
450
500
550
600
650
700
Март Юни Септември Декември Март Юни Септември ДекемвриMarch MarchJune June SeptemberSeptember December December
Textiles
Clothing
Average gross wages in the T&C industry (in BGN) 1 EUR ≈ 1,96 BGN
T&C industry in Bulgaria
Energy Efficiency Conference, Budapest, 12.05.2016
About Pirin-Tex
Products:
Men’s and ladies’ upper garments:
Suits
Jackets
Trousers
Skirts
Waistcoats
Shirts & blouses
Business activities:
Ready-made garments• Production• Retail
Product development• Pattern-making• Prototyping• Grading• Optimizing• Plotting
Garment Washing & Dyeing
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About Pirin-Tex
Additional activities:
Waste collection
Vocational training
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Does it make sense?
Engaging in energy efficiency
Energy Efficiency Conference, Budapest, 12.05.2016
Constantly rising prices of oil, natural gas and electricity
Lack of technological development
Legal obligations
Sustainable and environment-friendly production
Why?
Responsibility for each major player in the European garment industry to improve in all technical sectors related to their businesses
Energy Efficiency Conference, Budapest, 12.05.2016
Diesel price boom
€ 0,20
€ 0,30
€ 0,40
€ 0,50
€ 0,60
€ 0,70
€ 0,80
€ 0,90
€ 1,00
€ 1,10
2003 2004 2005 2006 2007 2008
Price perlitre ofdiesel inBulgaria
Price per litre
Energy Efficiency Conference, Budapest, 12.05.2016
€ 0,040
€ 0,045
€ 0,050
€ 0,055
€ 0,060
€ 0,065
€ 0,070
Jan
-03
Jul-
03
Jan
-04
Jul-
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Jan
-05
Jul-
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Jan
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Jul-
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Jan
-12
Jul-
12
Jan
-13
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Jan
-14
Jul-
14
Jan
-15
Jul-
15
Jan
-16
Regular rises in electricityprice
Price per kW/h
Energy Efficiency Conference, Budapest, 12.05.2016
Natural gas – unstability in prices
Price per m3
€ 0,40
€ 0,45
€ 0,50
€ 0,55
€ 0,60
€ 0,65
€ 0,70 Natural gas price
Energy Efficiency Conference, Budapest, 12.05.2016
Energy base restructuring
37%
63%Electricity
Diesel
2005 2008
53%47%Electricity
Naturalgas
2012 2015
54%
46% Electricity
Natural gas
Energy Efficiency Conference, Budapest, 12.05.2016
How do we measure it?
KWhminute
Energy input per production output
Defining energy efficiency in the company
What is energy efficiency?
EE =
Production output measured in standard minutes
Energy input measured in KWh
0,04
0,05
0,06
0,07
0,08
0,09
0,10
20
03
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04
20
05
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20
16
KWh/minute in Pirin-Tex
Energy Efficiency Conference, Budapest, 12.05.2016
Organisational measures:
Entering the free electricity market
Discipline among the staff regarding energy
use
Restructuring the fuel base
Constant monitoring of energy costs
Achieving energy efficiency -our experience
PIRIN-TEX
Energy Efficiency Conference, Budapest, 12.05.2016
Energy monitoring
Energy Efficiency Conference, Budapest, 12.05.2016
Technical measures:Insulation of hoses and
pressing forms
Installing controllers to all steam-heated machines
Changeover to LED-lighting
Correction of oversized steam boilers and piping
Adjustment of pressing programmes
Use of residual heat
Achieving energy efficiency -our experience
PIRIN-TEX
Energy Efficiency Conference, Budapest, 12.05.2016
Insulation steam pipes and steam machines
Insulation of ironing forms Insulation scheme forms
of ironing
Insulation of pipes
Energy Efficiency Conference, Budapest, 12.05.2016
Hot water
Compressors
Ho
t wate
r
DryerWashing machine
Hot water
receiver40°-60°
Sanitary needs
Heat exchanger
Steam boiler
Steam 168° °
Production facility
Ad
min
istr
atio
n
Low temp.
heating boiler
75°
Residual heat
Exhausted hot air
LAUNDRY
Water supply 18°°
60°
85°
Energy efficiency through residual heat
Energy Efficiency Conference, Budapest, 12.05.2016
8 000
9 000
10 000
11 000
12 000
13 000
14 000
15 000
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
2300 employees
3300 employees2000 employees
Energy consumption trend –Savings achieved
MW/h per year
PIRIN-TEX
Energy Efficiency Conference, Budapest, 12.05.2016
What savings we have made
Measure
Saved amount
for the period
(2008-2014)
Amount saved
on average per
1 year
Yearly amount
saved on
average per 1
worker
Changing the
energy source 910 000 € 130 000 € 39,40 €
Installing of
controllers to all
steam-heated machines
1 102 500 € 157 500 € 47,70 €
Entering the
free electricity
market805 000 € 115 00 € 34,90€
TOTAL: 2 817 500 € 402 500 € 122,00 €
Energy Efficiency Conference, Budapest, 12.05.2016
Energy Efficiency Conference, Budapest, 12.05.2016
Lessons learnt
Keep energy accounting!E.g. through the SESEC/SET tool
Regularly monitor and analyze your energy consumption and energy costs
Spot the leaks and take measures to save energyNot necessarily financial investments
PIRIN-TEX
The SESEC projectPIRIN-TEX
Started in 2012 by industry incentive
Aimed specifically at the garment industry
Part of the “Energy made-to-measure” campaign across the European T&C industry
Energy Efficiency Conference, Budapest, 12.05.2016
SESEC & SET projectsPIRIN-TEX
Clothing industry
Textile industry
COMMON PLATFORM: www.em2m.euEnergy Efficiency Conference, Budapest, 12.05.2016
An easy way to improve your energy efficiency
PLAN• “Energy made-to-
measure” online platform
CHECK• Audit internally your
current energy stand
ACT
• Apply the recommended best practices
PIRIN-TEX
Energy Efficiency Conference, Budapest, 12.05.2016
Title
Thank you for your attention!
Bertram RollmannPirin-Tex EOODBG 2900 Gotse Delchev50 Drama str.E-mail: [email protected]