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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



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.



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.



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



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



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


GHG emission reduction

303.7 tons

Total 13 40,300 39,182

Water Saving: 10,997 m3


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



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



# 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.

-



# 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



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



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



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 : [email protected]

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.



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)



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



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



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.



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.



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



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.



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)



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



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



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.



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.



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.



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



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.



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.



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.



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


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.


feasibility

Environmental


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



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.


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.


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



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.



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.


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



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.


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.


feasibility

Environmental


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.



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.



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%.



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



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.



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.



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:


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


environment

7

Note: Relevant checklist is shown in the Annex



3.5 Opportunities in Chemical Inventory



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


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.


environment

4 Spilled materials and liquids should be cleaned up

immediately.


environment

5 Sufficient toolkit for clean up the spilled chemicals

could be provided.


environment

6 Restricted Substances List (RSL) could be displayed in

the main chemical store as well as sub-store.


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.


environment

Segregation of waste on the basis of type and

department.


environment

Waste minimization efforts based on the monitoring

and analysis of segregated waste.

Recycle/ reuse options after waste minimization efforts

may be explored.


environment



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.



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


awareness and compliance

3 Proper labelling waste and segregation of waste Minor Ensure environmental


4 Waste management procedures’ development and

training



5 Establish a procedure to identify the

environmental aspects.



6

Reuse of ETP water could be a significant

improvement creating zero discharge system in the

factory.

Major Ensure 3R Principal and

regulatory compliance



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


GHG reduction: 31.65 tons

Utility 7 39,200 36,777

Power saving: 268,633 Nm3


GHG emission reduction

303.7 tons

Total 13 40,300 39,182

Water Saving: 10,997 m3


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.



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)


5 Annex


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


S.


%

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


S.


%

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


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
