energy efficiency in the clothing...

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;


• 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



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



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



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


About Pirin-Tex

Additional activities:

Waste collection

Vocational training


Does it make sense?

Engaging in energy efficiency


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


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


€ 0,040

€ 0,045

€ 0,050

€ 0,055

€ 0,060

€ 0,065

€ 0,070

Jan

-03

Jul-

03

Jan

-04

Jul-

04

Jan

-05

Jul-

05

Jan

-06

Jul-

06

Jan

-07

Jul-

07

Jan

-08

Jul-

08

Jan

-09

Jul-

09

Jan

-10

Jul-

10

Jan

-11

Jul-

11

Jan

-12

Jul-

12

Jan

-13

Jul-

13

Jan

-14

Jul-

14

Jan

-15

Jul-

15

Jan

-16

Regular rises in electricityprice

Price per kW/h


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 base restructuring

37%

63%Electricity

Diesel

2005 2008

53%47%Electricity

Naturalgas

2012 2015

54%

46% Electricity

Natural gas


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

20

04

20

05

20

06

20

07

20

08

20

09

20

10

20

11

20

12

20

13

20

14

20

15

20

16

KWh/minute in Pirin-Tex


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 monitoring


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


Insulation steam pipes and steam machines

Insulation of ironing forms Insulation scheme forms

of ironing

Insulation of pipes


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


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


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 €



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


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


Title

Thank you for your attention!

Bertram RollmannPirin-Tex EOODBG 2900 Gotse Delchev50 Drama str.E-mail: [email protected]

mailto:[email protected]

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