Cleaner Production

1. BEST ENVIRONMENTAL MANAGEMENT
PRACTICES
(Cleaner Production Options)
Textile Industry of Pakistan

2. What is the methodology of best environmental
management practices?
“The continuous application of an integrated preventative
environmental strategy applied to processes, products
and services to increase eco-efficiency and to reduce
risk for human and the environment”

3. Classification of Management Practices Options for
Textile Industry
 Good Housekeeping Practices
 Resource Conservation
 Process/Chemical Usage
 Cleaner Technologies

4. Good Housekeeping Practices
 Maintenance of Equipment
 Prescreening of Inventory
 Chemical Handling Practices

5. Maintenance of Equipment
Good Housekeeping Practices
Symptoms of Problems Leakages of oil, water,chemicals,steam
Improper Chemical dosing
Rare Machine, equipment and vessel cleaning
Actual Problems  Awareness but lack of willingness
 Not in the list of priority
Lack of proper staff
Plans but no proper implementation
Action Assignment of proper resources
Set as first priority
Implementation on continual basis
Cost/Resource Requirement No direct cost is involve
Performance Indicator Aesthetic improvement of industry
Savings in resources
Minimization of pollution load

6. Prescreening of Inventory
Good Housekeeping Practices
Symptoms High rejection
Large volume of inventory
Problems No Quality Control at this stage
QA Department under production
Fewer personnel for testing
Action Periodic Quality Checks for concentration and
Viscosity of Chemicals, Count and
Construction/Composition of Fiber/Fabric
Acquisition of MSDS from Vendors
Cost/Resource Requirement No direct cost is involved
Performance Indicator Less usage of raw material and chemicals
Low wastages

7. Chemical Handling Practices
Good Housekeeping Practices
Problems Improper Storage, Transportation and Handling
Spillage
Wastage
Action Proper Storage Facility
Segregation of Chemicals
Use of Liquid and Granular Dyes and Chemicals
Labeling of Chemicals
Training of Staff on Chemical Handling &
Transportation
Cost/Resource Requirement No direct cost is involved
Development of External & Internal Training Program
Performance Indicator Less usage of Dyes and Chemicals
Reduction in Pollution Load
Occurrence of Accidents minimized

8. Resource Conservation
 Installation of Water Flow meters
 Reuse of Bleach and Dye Bath
 Reuse and Recycling of Cooling & Condensate Water
 Reduction of Water Consumption in Printing Cleaning
 Minimization of Energy Consumption in Stenter
 Reduction in water consumption in washing ranges
 Installation of Economizer at Boiler
 Calculation of Boiler Efficiency

9. Installation of Water Flow meters
Problems Not observable at early stage like cancer
Action Resources can only be conserved if water consumption
is optimum in the industry. Water optimization can not
be achieved without water monitoring. For water
monitoring and its controlled use, water flow meters of
appropriate size and types will be installed at the source
and at all the major water utility areas and machines
Cost/Resource Requirement 10,000-15000 Rs.
Saving of 10-15 % water used
Performance Indicator Identification of areas of high water consumption
Basis for water reduction plans

10. Reuse of Bleach and Dye Bath
Resource Conservation
Concerns Drain of Costly Chemicals and Dyes which can be reused
Action Using continuous scour wash water to batch scouring
Reusing scour rinses for desizing
Reusing mercerization wash water for scouring
Reusing bleach wash water for scouring
Use of exhausted dye bath for next run
Cost/Resource Requirement Cost includes piping, pump and tanks cost, which will be
approximately 150,000 Rs for each recycling option
Incase of dye bath reuse in addition to above shade
analyzer will be required which costs 250,000 – 300,000
Local expertise and fabricators available
Performance Indicator Water conservation
Cost saving in terms of less amount of chemicals and dyes
usage
Low pollution load

11. Reuse and Recycling of Cooling & Condensate Water
Resource Conservation
Concerns Drain of hot water which comes after cooling various
machineries specially jets and singeing
Drain of Boiler’s Condensate Return
Action Recycle of drain hot water and condensate return in various
functions where hot water is required
Cost/Resource Requirement Cost of cooling water reuse will be approx 100,000 Rs.
Cost of reuse of condensate return will be approx 100,000 –
150,000 Rs. Pay back with in four months
Local expertise and fabricators available
Steam condensate
Performance Indicator Water and energy conservation
Reduction of wastewater

12. Reduction of Water Consumption in Printing Cleaning
Resource Conservation
Concerns Use of water for cleaning belt even when the machine is not running
Waste of printing paste after each batch change over
Use of fresh water for cleaning squeegees, screens and buckets
Action Provision for stoppage of running water when machine stops
Use of shut off valves in water hoses
Manual/Mechanical removal of printing paste
Reuse of cleanest part of rinsing water instead of using fresh water for
cleaning.
Filtering of screen wash water by chemical means and its reuse.
Use of glue for blanket which do not require repeated washing
Use of multi screen washers using spray nozzles.
Cost/Resource
Requirement
Cost incurred for reuse of rinsing water will approximately be 150,000 –
200,000 Rs.
Performance
Indicator
Water and energy conservation
Reduction of wastewater
Reduction of dye paste

13. Minimization of Energy Consumption in Stenter
Resource Conservation
Concerns Wastage of hot exhaust gases
Use of low efficiency burners
Use of low efficiency heating systems
Action Installation of heat exchangers and optimization of exhaust
air flow
Controlling moisture content of feed fabric
High efficiency burners to be used
Use of indirect gas firing systems
Proper encasement of stenters
Cost/Resource Requirement Cost incurred for heat exchangers will be approximately
100,000 – 150,000
Cost for encasement of stenters will be dependable on
condition of insulation
Performance Indicator Energy conservation

14. Reduction in water consumption in washing ranges
Concerns Use of a large quantity of high temperature water at
washing
Action The consumption can be brought down by adjustments in
the process parameters. For this purpose, interactive
software can be used to determine specific water usages at
different sets of such parameters before being applied in
practical.
Cost/Resource Requirement Only testing equipment for conductivity measurement is
required to get washing efficiency.
Performance Indicator Water and energy conservation
Reduction of wastewater
Resource Conservation

15. Installation of Economizer at Boiler
Concerns Loss of waste heat from boilers stacks
Action Flue gas thermal energy can be used to heat boiler feed
water by the installation of an economizer
Cost/Resource Requirement  650,000 Rs.
Performance Indicator energy conservation
Resource Conservation

16. Calculation of Boiler Efficiency
Resource Conservation
Concerns Boilers are mostly old enough to have good efficiency.
Action Actual efficiency to be calculated for making the further
decisions
Cost/Resource Requirement No cost is involved except for a gas meter at the boiler to
get the consumption.
Performance Indicator energy conservation

17. Process and Chemical usage
Process Modification
Chemical Substitution
Better Process Control
Process Control Laboratory
Process Modification and Chemical Substitution is mainly
related with Buyers requirement, Quality Control and Costing. It
is observed that this issue is already hotly being pursued by
management to remain competitive and is a priority issue.
Process and Chemical Usage

18. Better Process Control
Concerns High rejection, low quality, production breakdowns
Action Standardization and dissemination of process parameters
Maintenance and calibration of gauges and equipment
Regular Logging and documentation of controls variables
On floor testing and measurements of key variable
Cost/Resource Requirement No direct cost is involved except for few equipment of
nominal costs.
Performance Indicator Identification of bottlenecks
Increase in A-Quality products
Process and Chemical Usage

19. Process and Quality Control Laboratory
Concerns Production often overshadows Quality
Laboratory is generally considered as non value adding
entity
Action Independent laboratory be established
Quality assurance at every level
Providing Assistance to production and not hurdle
Cost/Resource Requirement Costs depends upon the type of industry
Performance Indicator Increase in market share
Market appreciation
Process and Chemical Usage

20. Cleaner Technologies
 Caustic Recovery from Mercerization
 Recovery of Printing Paste from Supply System
 Using Counter Current Washing Methods

21. Caustic Recovery from Mercerization
Cleaner Technologies
Concerns Discharge of high concentrated caustic in effluent after mercerization process
Action Recovery of caustic in three stage evaporation process
Through caustic recovery plant the 5Be weak lye can be concentrated up to
25Be solution
Cost/Resource
Requirement
Cost incurred for caustic recovery plant will be approx 3 – 3.5 Million Rs.
Local expertise and fabricators available
Performance
Indicator
Approximately 50% saving of caustic soda
Reduction of caustic soda loading in effluent

22. Caustic Recovery from Mercerization
Cleaner Technologies

23. Recovery of Printing Paste from Supply System
Cleaner Technologies
Concerns Wastage of dye paste after each batch run
Action Use of paste dispensing system with provision of balls in the supply system
After finishing a print run the ball is pressed back by air pressure which pumps
the paste back into the drum for reuse
Use of minimum lengths of piping.
Use of online washing systems
Cost/Resource
Requirement
Dependent on the type of systems
Performance
Indicator
Approximately 50% - 75% wastage is reduced
Reduction of dye paste in effluent

24. Recovery of Printing Paste from Supply System
Cleaner Technologies

25. Using Counter Current Washing Methods
Cleaner Technologies
Concerns Wastage of rinse water
Action Horizontal or vertical washers can be used in principal of counter flow with
respect to flow of fabric
Cost/Resource
Requirement
25,000 to 35,000 Rs.
Pay back with in days
Performance
Indicator
Reduction in consumption of water and energy

26. Using Vertical Washing Methods
Cleaner Technologies

27. References
 Identification and reduction of pollution sources in textile wet processing by
Brent Smith
 Integrated pollution prevention and control, reference document on Bet
available techniques for the textile industry by European Commission
 Identification and evaluation of Best available technologies economically
achievable (BATEA) for textile mill effluents by Merbek Consultants Canada
 Pollution prevention studies in the textile wet processing industry by
Department of Civil Engg., VPI &SU, Virginia
 Best management Practices for pollution prevention in the textile industry by
EPA (Manual)