Module 6: Understanding processes and assessing energy

performance of textile and garment factories

Prepared by: Dr. Jurgen Hannak, M. Salman Butt

LU 6.1: Energy Performance in Textile Process
At the end of this module you will be able to…

Assess and conduct energy balance of textile and garments processes

Resources

IFC Environmental, Health, and Safety Guidelines for Textile

Manufacturing

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Typical production and process flows in Spinning, Weaving, Dyeing,
Finishing and Garment Making

Input-output aspects

Content
Key performance benchmarks

Energy balance of Textile and Garment processes

EE Opportunities in processes

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Textile Value Chain

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Yarn manufacturing/ Spinning

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Yarn Production
Group work

• In your groups, develop typical energy flows and losses in Yarn

Production process using the I.P.O. diagram.
• Present your results on flip chart in Information Market format

• Time 15 min

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Yarn Production (aka Spinning)
Example Material Flow Chart QC 1
QC 2
Mixing, Plucking, Blending
Multimix, Beating
QC 3 Sorting, Beating, Scutcher
QC 4 Carding
QC 5 Breaker Drawing
QC 6 Finisher Drawing
QC 7 Simplex
QC 8 Ring
QC 9 Auto Cone

Energy: 141 kWh Energy: 264 kWh

Cotton Bales

QC 1 QC 2 QC 3 QC 4
W W W W Sliver
A Blended A Beat Cotton AS Laps A
S S TE S
T T T
E E E

Saleable Waste Saleable Waste Saleable Waste Reusable Waste Saleable Waste Reusable Waste
•Contamination •Contamination •Contamination •Short Fibre Cotton •Lickerin Waste •Handling waste
•Dust •Dust •Dust •Used in other processes •Imputities (Cotton fibre)
• Short Cotton fibre • Short Cotton fibre • Short Cotton fibre •Short fibre & fibre Neps
•Dust

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Yarn Production (aka Spinning) QC 1
QC 2
Mixing, Plucking, Blending
Multimix, Beating
QC 3 Sorting, Beating, Scutcher

Example Material Flow Chart QC 4

QC 5
Carding
Breaker Drawing
QC 6 Finisher Drawing
QC 7 Simplex
QC 8 Ring
QC 9 Auto Cone

Energy: 317 kWh

Energy :952 kWh Energy :257 kWh

QC 5 QC 6 QC 7 QC 8 QC 9 Inventory

W W W W W
A Drawing Sliver A Drawing Sliver A Roving Bobbin Cones
A A
S S S S S
T T T T T
E E E E E

Material Waste Material Waste Material Waste Material Waste Material Waste
• Short Fiber • Short Fiber • Short Fiber • Pneumafil • Faulty Yarn
• Yarn Loss
(mishandling)

Source: Material Flow Cost Accounting of a Spinning Mill by Espire Consult

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Material Flow Cost Accounting - Spinning
Example Material Flow Chart

Source: Material Flow Cost Accounting of a Spinning Mill by Espire Consult

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Material Flow Cost Accounting - Spinning
Example Material Flow Cost Accounting

Source: Material Flow Cost Accounting of a Spinning Mill by Espire Consult

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Material Flow Cost Accounting - Spinning
Example Material Flow Cost Accounting

Cost Material Energy System Disposal Total

PKR 131,337 12,967 4,499 148,803

Product
% 79% 79% 79% 72%

PKR 34,097 3,447 1,196 20,331 59,071

NPOs
% 21% 21% 21% 100% 28%

Source: Material Flow Cost Accounting of a Spinning Mill by Espire Consult

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Spinning Energy Benchmarking - Pakistan
For 100% Cotton Yarn

Source: UNIDO Sectoral Analysis on Renewable Energy and Energy Efficiency in Pakistan (2019)

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Spinning Energy Consumption Ranges

Source: UNIDO Sectoral Analysis on Renewable Energy and Energy Efficiency in Pakistan (2019)

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Energy Balance of a Spinning Process
7%
Example Energy Balance 13%

14%

• Main Energy type: Electrical Power 17%

• Major utility: Compressed Air and 49%

Humidification Plant
• Largest consumer of energy : Ring Frames
Back Processes (Mixing till Blow room)
Carding
Drawing & Simplex
Ring
Auto Cone

Source: Material Flow Cost Accounting of a Spinning Mill by Espire Consult

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Yarn Production
Energy Performance Improvement Options

• Compressed air system

✓ Demand side Pressure optimization
✓ Leakage reduction
• Ventilation and Humidification Plant
• 3-5% positive pressure between supply and exhaust air
• Automated controls of humidification system
✓ Optimization of Supply and Return Fans e.g. FRP Fans, Air Changes..
✓ Optimization of Showering System e.g. Fogging System, Humidity feedback control…
• Machinery
✓ Automation & synchronization of transportation fans in blow room
✓ Avoiding fluff accommodation in machines to reduce friction and yarn breakages (especially Ring
frames and Auto Cone)
✓ Automation of machine speed according to yarn tension and loading in Ring frames

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Textile Weaving

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Weaving
Group work

• In your groups, develop typical energy flows and

losses in Weaving process using the I.P.O. diagram.

• Present your results on flip chart in Information Market

format

• Time 15 min

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Weaving
• Common Methods • Air Jet Loom Application
• Power Looms Suitable for
• Water Jet Looms • plain and textured fabrics
(mostly synthetic fibre) • fine high density fabrics
• Air jet Looms • High speed bulk production
• Rapier Looms
• Rapier Loom Application
Suitable for
• multi-color weft fabrics
• yarn-dyed fabric
• double-layered velvet fabrics
• terry fabrics
• decorative fabrics
Photo credit: M. Salman Butt, Espire Consult • Much slower than air jet loom
• Moderate energy consumption
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Energy Balance – Example (Weaving)

Source: Espire Consult

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Weaving Energy Consumption Ranges

Source: UNIDO Sectoral Analysis on Renewable Energy and Energy Efficiency in Pakistan (2019)

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Energy Efficiency Options in Air Jet Looms

• Control Air Leakages in looms

✓ Leakages up to 15-20% of total air demand have been observed Common Air Leakages in
Air Jet Looms
• Optimize compressed air pressure according to yarn count
✓ Mostly, higher air pressure is provided to cover for pressure loss due Relay Valve

to leakages; hence inducing more leakages

Tuck Inn
• Automate the air conditioning parameters based on real-time
temperature, and humidity
Suction Mouth
✓ Don’t forget to adjust air changes according to number of machines
operating in the area; and temperature and humidity conditions Pre-winder
• Maintain Air Balance among Supply and Return air
Internal PVC Link Pipes
✓ Maintaining positive displacement (~3-5%) facilitates fluff removal
from air, reducing fluff accumulation in the looms hence maintaining
energy performance
• Production Planning
✓ Improve machine up-time to improve energy performance

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Textile Wet processing

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Fabric Wet Processing and Finishing

Pre-treatment Dyeing & Printing Finishing

Shearing Dyeing Stenter

Combing Printing Water proofing
Singeing, Desizing Wrinkle free treatment
Scouring and Bleaching Softening treatment
or Solomatic Bleaching Flame retardancy
Washing treatment
Mercerising, Drying Odour resistance
Stenter treatment
Shrinking Oleophobic treatment
Biocide treatment
Coating

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A-Fabric Pre-treatment (Open Width)

• Singeing-Desizing
• Batching
• Post Desizing Wash
• Scouring
• Bleaching
• Washing
• Drying
• Mercerizing (If cotton dyeing is required)

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Singeing

Methods
• Direct Flame application on fabric
• Passing fabric over a Heated Copper Plates/rollers

Energy Efficiency Options

• Controlling flame size and fabric roll speed
• Variable Flame Width
• Improve burner efficiency
• Recover and reuse cooling water

Parameter O2 CO NOx NO NO2 CO2 SO2 Flue

Temp.
% ppm ppm ppm ppm % ppm ◦C
Standard 649 195 603
(PEQs)
New Singeing 19.22 145 1.2 0 1.2 0.99 0 139
Machine

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De-sizing
If Singeing is done, De-sizing is conducted in the
Singeing Quenching batch
Methods vary according to size applied
• Enzymatic (Process control!; for starched based sizes)
• Oxidative (usually for different types of textiles, applying
hydrogen peroxides, caustic soda) – Rarely used
• Use of acids (sulfuric or hydrochloric acid)
• Washing out with hot water and wash soda

Energy Efficiency Options

• Waste water heat recovery
• Improving Insulation of Hot Water Baths
• Optimizing process using pH, temperature and speed
with automation

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Bleaching
Common methods
• Hydrogen peroxide (H2O2)
• Sodium hypochlorite (chlorine bleaching lye,
NaClO)
• Sodium chlorite (NaClO2)
• Sulphur dioxide (SO2)

Energy Efficiency Options:

• Waste water heat recovery (~6m payback)
• Improved heat exchanger material (e.g. Stainless
Steel) allowing longer life and reduced corrosion;
hence improving heat exchanger efficiency

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Mercerising

Refining process with the aim of improving tensile strength, dimensional stability and
improved absorbency for consequent dyeing
Methods
• Sodium hydroxide bath with heat treatment under tension
or without tension, then neutralization with an acid plus
washing
• Ammonia (very rare)
Energy Efficiency Options
• Optimizing steam in-take of Drying Rollers
• vendors claim ~14% steam saving but its not
verifiable; companies have experienced
improvement in process quality and control
• Waste water heat recovery
• Caustic Recovery (shown on next slide)
• Reusing Mercerising wastewater in scouring Photo Source: textiletoday.com.bd

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Recovering NPOs – Caustic Recovery Plant
• NaOH is re-used in Mercerising (24 – 30 Baume)
• H2SO4 consumption is reduced at Effluent Treatment
• Hot water available to feed into the processes – saving steam
• Return on Investment ~ 3 years

Source: IFC

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B- Dyeing
Group work

• In your groups, develop typical energy flows and losses in

Dyeing process using the I.P.O. diagram.
• Present your results on flip chart in Information Market format

• Time 15 min

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Dyeing approaches

• Material dyed • Dyeing techniques

• Twine • Gel dyeing (in the production of artificial
• Yarn fibres)
• Knitted / woven fabric • Pigment dyeing (with binder)
• Garment • Diffusion dyeing
• Exhaust dyeing
• Process
• Ozone dyeing
• Batch
✓ Ozone can be used on indigo or black
• Continuous
sulfur fabrics.
✓ Use of ozone requires up-front
investment in the ozone machine and
the generators, along with safety
training for workers.

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Fabric Dyeing

• Cellulosic Fabric Dyeing (Cotton, Viscose, lyocell, linen, hemp etc.)

✓ Reactive Dyes
✓ Temperature Required around 65 deg C for which machines work at
atmospheric pressure

• Synthetic Fabric / Blended (Polyester, PC, Nylon etc.)

✓ Disperse Dyes
✓ Temperature Required Above 100 deg C for which machines work above
atmospheric pressure

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Fabric Dyeing

• Batch/Discontinuous
✓ Open Width form Dyeing
Open Jiggers and Pressure Jiggers, Beam,
✓ Rope form Dyeing
o Jets, Winches, Soft flow machines / HT machines (Knitted fabric)
• Semi Continuous
✓ Pad Batch / Cold Pad Batch (CPB)
o (For Cellulosic Materials and alternative to reactive dyeing)
✓ Pad Jig
✓ Pad Roll
• Continuous
✓ Chemical Steam Pad
✓ Pad Dry Steam (PDS)
✓ Pad Dry Pad Steam (PDPS)
✓ Pad Dry Cure (PDC)
✓ Pad Thermosol Dyeing

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Dyeing – Basic steps
Step 1
• Colouring agents (mostly powder form, dye) dissolved in "dye liquor"
according to a given recipe
• Dyestuffs diffuse from "liquor" to the substrate
Step 2
• Dyestuff accumulates on the surface of the yarn/fabric => question of the
affinity of the dyestuff to the fibre
Step 3
• Penetration of the fibre with the dye (slower than surface accumulation) =>
prerequisite given for hydrophilic fibres (micropores); in the case of
hydrophobic fibres => heating necessary (often over 100 degrees)
• Addition of salts to overcome electrostatic surface barriers
Step 4
• Fixation of dyestuffs (heat, auxiliaries)

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Benchmarks to look out for in dyeing

Liquor ratio Fixation rate

• Dye bath = solvent (usually water) as well • Percentage of dye used that
as all dissolved, emulsified or dispersed remains on the material to be
components contained therein such as dyed.
dyes, pigments, chemicals and auxiliaries.
• Different extraction rates
• Liquor ratio (LR) = Ratio of quantity of depending on dye and
fabrics to dyebath liquor (kg to kg or kg to process
liters)
• Mostly referred to in batch-dyeing
• Aim => To achieve low liquor ratios

For example: 200 kg fabrics, 1400 ltr dyebath

=> LR 1:7

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Batch Dyeing

bobbin dyeing 1:8 – 1:15

Hank dyeing, LR
1:12 – 1:25

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Package Dyeing – Knitware

Jig Dyeing
LR 1:3 – 1:6

Beam dyeing)
LR 1:8 - 1:10

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„Winch“ dyeing

LR 1:15 - 1:40

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„Jet“ Dyeing machines
Also callsed SoftFlow Machines

LR 1:4 - 1:10

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Feed-through dying maschines

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Energy Efficiency Options in Dyeing
• Using low TDS water for dyeing and post dyeing operations helps reducing
✓ Dyes, chemicals and auxilliary consumption
✓ Process time
✓ Liquor Ratio
• Improved heat exchanger material (e.g. Stainless Steel) allowing longer life and
reduced corrosion; hence improving heat exchanger efficiency
• Low Liquor Ratio and use of high fixation dyes helps reducing
✓ Steam consumption
✓ Water pumping cost
✓ Process time → electrical energy
• Improve insulation of machine
• Wastewater heat recovery
✓ Additionally, an insulated hot water storage tank might also be needed
if hot water is to be used in process
• Cooling water recovery and reuse

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Switching to Cold Pad Batch (CPB) instead of conventional reactive dyeing

• It is not possible to switch to cold pad batch dyeing for every reactive dyeing setup
(High precision and control required)
• However, the associated benefits encourage the textile mills to put in more efforts
✓Up to 50% energy consumption reduction
✓Up to 50% water consumption reduction and reduced wastewater
✓No use of salt, reducing the pollution load of generated wastewater
✓The fabric don’t undergo abrasion so dyed fabrics have smoother surface

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Question
What are the Energy benefits of reducing
liquor ratio and improving fixation in dyeing?

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C- Printing
Group work

• In your groups, develop typical energy flows and losses in

Printing process using the I.P.O. diagram.
• Present your results on flip chart in Information Market format

• Time 15 min

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Fabric Printing

• In industry 03 types of machines are used for printing the fabric

– Rotary Printing

– Flat bed / Panel Printing

– Digital Printing

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Fabric Printing

• Normally fabric is printed through two methods

✓ Pigment Printing: Surface Printing where design is fixed with the help of
binders and fixers. Curing is done through dry heat in curing chambers
above 100 oC (depending upon the colour recipe)

✓ Reactive Printing: The colour design is attached to fabric as a result of

chemical reaction. Curing is done in a high temperature (close to 100 oC)
moist environment. This type of fabric requires washing after printing.

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Energy Efficiency Options in Printing

• The Curing chamber is the main area of interest in which air is heated
either through direct natural gas firing or indirect air hot thermal oil

✓ Automation of curing chambers through linking fans and fuel firing with
exhaust moisture and temperature of each chamber

✓ Heat Recovery from exhaust flue gases

✓ Insulation of curing chambers

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D- Finishing

• In Textiles two types of Finishing Processes are used

✓ Chemical Finishing in Stenter Machines: Either direct firing of natural

gas or indirect heating through Thermal Oil

✓ Mechanical Finishing: Mostly steam is used for indirect heating at

following machines
▪ Calendars
▪ Comfort
▪ Sanforizer

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D- Finishing

• In Textiles two types of Finishing Processes are used

✓ Chemical Finishing in Stenter Machines: Either direct firing of natural

gas or indirect heating through Thermal Oil

✓ Mechanical Finishing: Mostly steam is used for indirect heating at

following machines
▪ Calendars
▪ Comfort
▪ Sanforizer

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Stenter
Group work

• In your groups, develop typical energy flows and losses in a

Stenter using the I.P.O. diagram.

• Present your results on flip chart in Information Market format

• Time 15 min

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Stenter

Energy Efficiency Options:

• Modulation of Thermal Oil Heater/ Gas Burners according to temperature
requirement in Stenter
• oil temperature of +50C is required)
• Automation of stenter exhaust according to required temperature, moisture
and feed rate of fabric
• requires installing VFD on ID/FD Fan, and fabric moisture sensors
• Other Benefit: Results in improved quality by reducing shade variation
• Exhaust air waste heat recovery system
• Requires an efficient filter before the waste heat recovery system
• CAUTION: install proper control systems to avoid fire in the filter
Photo Source: Sekkeli, Mustafa & Kececioglu, Fatih.
(2012). SCADA based an energy saving approach to
operation of stenter machine in a textile plant using waste
heat recovery system. Tekstil ve Konfeksiyon. 03. 248-257.

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Example Calculations
Parameters Unit Values
Calculation for 1 stenter
Exhaust Air flow kg/s 2.45
o
Stenter exhaust temperature T1 C 160
o
Target exhaust temperature T2 C 100
o
Temperature Reduction dT C 60
Operational hours Hours/year 7,200
Specific Heat of Air kJ/kg-C 1
Available energy kJ/h 529,200
Recoverable energy (@70%
GJ/y 2,667
efficiency)
Coal saving per stenter Tonne/y 143
Financial Saving per stenter USD/y 17,838
Calorific Value of Coal 23.36 GJ/tonne
Investment per stenter USD 25,000 Emission factor of
Payback period months 17 Coal 0.089 tCO2/GJ
GHG emission reduction per stenter TonneCO2/y 298 Coal price 0.125 USD/kg

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Example Calculations
Parameters Unit Values
Calculation for 1 stenter
Exhaust Air flow kg/s 2.45
o
Stenter exhaust temperature T1 C 160
o
Target exhaust temperature T2 C 100
o
Temperature Reduction dT C 60
Operational hours Hours/year 7,200
Specific Heat of Air kJ/kg-C 1
Available energy kJ/h 529,200
Recoverable energy (@70%
GJ/y 2,667
efficiency)
Coal saving per stenter Tonne/y 143
Financial Saving per stenter USD/y 17,838
Calorific Value of Coal 23.36 GJ/tonne
Investment per stenter USD 25,000 Emission factor of
Payback period months 17 Coal 0.089 tCO2/GJ
GHG emission reduction per stenter TonneCO2/y 298 Coal price 0.125 USD/kg

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Garment Making

Fabric Making and

Denim Yarn Dyeing Denim Garment Making
Finishing
Yarn Rope Weaving Cutting
Bleaching, Stitching
Washing, Dyeing, Singeing Desizing
Softening Desizing Washing
Sizing Mercerising Drying
Stenter Distortion / special
effects
Steam pressing
Packing

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Cut to Pack (Garments)

• This segment shapes up the final product ready for dispatch. It includes following areas;

✓ Pattern Making

✓ Cutting

✓ Stitching

✓ Packing

• Cut to Pack Units are human resource intensive so utilities like lighting, ventilation, thermal
comfort, drinking water etc. are required to maintained and can be inspected accordingly.

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Stitching Process Optimization

• Installing Servo Motors brings return on

investment typically within One year

• Additionally, 8-10% variation in process times

is usually observed; possible savings include;

✓ Electricity

✓ Compressed air

✓ Process time, resulting

in higher productivity Source: Box plot of a stitching process by Espire Consult

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Stitching Process Optimization

• Installing Servo Motors brings return on

Motor Type Loading Load (kW)
investment typically within two year
Clutch Motor On-load 0.638
• On-load time is 60% of the Cycle Time Off-load 0.2332
Servo Motor On-load 0.528
(normally this value is lower which would Off-load 0.0242
Sample measurements of stitching machine power consumption
increase saving potential)

• Calculate annual energy saving (assume

annual operation 7200 hrs)

Energy Saving = On-load 475 kWh + offload 602 kWh = Total 1,077 kWh

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Garment Washing
Group work

• In your groups, develop typical energy flows and losses in Garment

Washing process using the I.P.O. diagram.

• Present your results on flip chart in Information Market format

• Time 15 min

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Denim Garment Washing

Rinsing Bleaching

Stone
Rinsing Washing Neutralization
(abrasion)

KMnO4
Drying Neutralization
Application

Washing
Drying Softening
(abrasion)

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Denim Production – Washing

Mechanical processes Chemical processes

• Rinse wash • Acid wash, ice or snow wash
• Water jet fading • Hydrogen peroxide wash or bleach washing
• Stone wash • Enzyme wash
• Whiskering • Ozone fading
• Microsanding including sandblasting • Spray techniques
• Mechanical abrasion • Overdyeing and tinting
• Laser treatment

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Levi Strauss & Co. Water<Less™ Program

Low Liquor Ratio in Stone Wash

• Water savings counted: ½ Stone Wash bath

• Average water savings: 2.4 liters / jean
• Energy Saving: Steam used for ½ Stone Wash bath
• Frequency of use: Moderate
• Critical issues
✓ Back staining may occur if this technique is not properly applied.
✓ Low liquor ratio stonewash can be difficult in a belly washer machine.
✓ It is not recommended to use a liquor ratio below 3:1.
✓ Advances in enzyme and dispersant chemistry make this technique possible

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Levi Strauss & Co. Water<Less™ Program
Traditional Proposed
Combine desize and stonewash / enzyme wash
• Water savings counted: Two total baths, a de-size and a rinse Desizing Desizing + Stone
↓ ↓
• Average water savings: 11.8 liters / jean Rinsing Rinsing
↓
• Energy Saving: Electricity and Steam used for 2 baths Washing (Stone)
↓
• Frequency of use: High Rinsing
• Method
✓ When a stonewash or enzyme wash follows a desize bath in a finish
formula, it traditionally requires four baths: a desize bath, a rinse, a
stonewash or enzyme bath, and another rinse. Combining the desize step
with the stonewash/enzyme wash followed by a rinse reduces the process
to a total of two baths.
• Critical Issues
✓ Not recommended for fabrics that bleeds a lot.
✓ An extra dispersant in the bath may be required to avoid back staining.

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Levi Strauss & Co. Water<Less™ Program

Remove de-size step

• Water savings counted: One de-size bath

• Average water savings: 5.9 liters / jean
• Energy Saving: Electricity and Steam used for One de-size and One Rinsing bath
• Frequency of use: High
• Critical issues
✓ Possible if Water Soluble Sizing material is used in Denim Mill – needs
encouragement from the Brands / Buyers
✓ In the case of a heavy weight fabric or a fabric that is sensitive to abrasion, a rinse
step might still be necessary
✓ Challenges with shrinkage may arise

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Levi Strauss & Co. Water<Less™ Program
Increasing Ozone Concentration
• Water savings counted: A bleach bath and a generic neutralization bath
• Average water savings: 12 liters / jean
• Energy Saving: Electricity and Steam used for One bleach and One Neutralization bath
• Frequency of use: Moderate
• Method
✓ Higher concentrations of ozone achieve more pronounced lightening effects, effectively replacing many uses for wet
bleach baths.
✓ Lightening a garment with a wet bleaching agent typically requires three wet baths: a bleach bath, a neutralize bath,
and a rinse bath. If ozone use comes in the middle of a finish formula, it saves all three baths.
✓ If ozone use is the first step in a formula, it only saves two baths because the garments need to be wet before being
loaded into the machine.
• Critical Issues
✓ Ozone can be used on indigo or black sulfur fabrics only.
✓ Use of ozone requires up-front investment in the ozone machine and the generators, along with safety training for
workers

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Levi Strauss & Co. Water<Less™ Program
Spray potassium permanganate on raw garments
• Water savings counted: One neutralization bath
• Average water savings: 5.8 liters / jean
• Energy Saving: Electricity and Steam used for One Neutralization bath and One Drying
Cycle
• Frequency of use: High
• Method
✓ Applying the spray at the beginning of the finish formula – before the garments ever
get wet – allows the neutralization agent to be added to the first existing wet bath.
✓ The neutralization bath is removed, and the rinse that follows neutralization is also
potentially removed.
• Critical Issues
✓ This technique works best with dark finishes
✓ Be aware of potential back staining

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Drying Process

• Modulate steam pressure according to process temperature

requirement i.e. Shade, fabric weight, batch size etc. to
optimise steam use
• Majority companies don’t even install Steam Pressure
Reducing Valves with dryers and all dryers are provided
same pressure
• Assess possibility of recirculating the machine exhaust air
• This would require installing a fluff collector Jute bag (like
used in Carding Machine filters in Spinning industry) and
adding 30~40% fresh air
• May result in better heat exchange as well as reduction in
process time and Steam consumption

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Water Saving Duplication Rules

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Water Saving Duplication Rules

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Blow Cleaning in Distortion

• Install high pressure electric blower with custom nozzle

instead of using compressed air
• Reference calculations
✓ 03 pipes of 4mm internal diameter at each workstation
✓ Air consumption = 94 m3/h per workstation
✓ Cost saving per work-station = ~6,000 USD/y
✓ Investment for a high pressure electric blower = 500
USD
✓ Return on Investment = Immediate

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Key takeaways

• Often energy practitioners and consultants avoid assessing manufacturing processes in

detail when conducting energy assessments, whereas most significant and sustainable
energy savings are found in the manufacturing processes

• When assessing any process, first step is to develop an Input-Process-Output diagram

or an energy balance of that process. This reveals many facts about the nature and
manner of energy use and thus opens new avenues for energy saving

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Key takeaways

• Identify which manufacturing process are significant energy uses (SEUs) and develop
their Input-Process-Output diagrams with quantification of energy balance

• Identify which variables significantly affect energy performance of these processes

• Calculate cost impact of the energy NPOs / wastes

• Select improvement measures to reduce energy NPOs and calculate their financial
payback

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