Water mapping in a textile company revealed several opportunities to conserve on water and thermal energy through process optimisation and energy efficient design.
Benchmarking the bath ratio in a textile finishing company indicated a room for improvement through reducing that bath ratio. That reduction was achieved while monitoring the product quality to avoid any adverse impact, and consequently the company saved on water, chemicals, and energy.
Shifting from conventional drying to continous dryeing with an automatic conveyor supported this textile company to increase the productivity, reduce the steam demand, and improve the product quality.
Adopting a laser engraving machine with an efficient software is considered as a winnning measure for this textile company, as they now decreased the rework of products. This not only increased the productivity, but also reduced the specific energy and chemical consumption.
Another eco-innovative opportunity to save on water, energy and chemical consumption within jeans washing facility was to install micro-nano bubbles washing machines in place of the conventional washing machines. This technology was developed within the past few years, and proved success in various installations.
This practice illustrates the strength of a powerful information system, that is linked to an automation software can save on resources, and reduce the production time.
Mapping of water quality revealed that the effluent from the WWTP can be reused after some additional Reverse osmosis treatment. This practice illustrates the case of a textile company that managed to recycle 120 000 m3/year of water.
Water mapping highlighted that the bleaching machine used water in a once through design, where water from different washing stages is drained to the sewer network. Modification of the water network enabled the recovery of washing water for reuse in washing process.
The need for color correction in dyeing process necessitates decreasing the bath temperature to add the color correction, then gradually increasing the temperature. Therefore, reducing the number of color corrections, through assurance of the ingredients from the first time saves on energy and increases the productivity.
Through purchasing and installing of an Ozone-based washing technology, the jeans washing facility tremendously decreased the water and energy consumption, and eliminated the use of hazardous chemicals.