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1
HAMS Garments Ltd.
Sustainability Report (2016-2017)
Prepared by
Md. Riyajul Haq, Asst. Manager (Environment & Chemical)
HAMS Group
January 2017
2
EXECUTIVE SUMMARY
Introduction
HAMS Garments Ltd. has been working to adopt & implement various strategies and an
approach towards sustainability. As part of this work, water consumption, waste wastewater
generation and energy consumption are recorded. Besides, greenhouse gas emission and solid
waste inventory are maintained. The water & energy consumption, waste generation and
greenhouse gas emission are reviewed by HAMS Garments authority through sustainability
report which is formulated yearly. HAMS Garments authority sets target and define strategies
to reduce water & energy consumption as well as to improve environmental performance.
Water consumption Record
The main purpose of water metering system is; to track & measure total water withdrawal
from underground, total water consumption for production & domestic purpose and the total
wastewater generation from HAMS Garments Ltd.
Energy Consumption & GHG emission Record
In textile, energy is an important component and without this textile industry cannot be
operated. Energy resources are limited and these must be used reasonably and responsibly.
HAMS Garments Ltd mainly uses natural gas & diesel for generating power & steam.
Table: Total energy consumption record in GJ of HAMS Garments Ltd., from 2013 to 2016
Year 2013 2014 2015 2016
Energy in GJ 215473.2 216972.9 252011 275034
Table: GHG emission record from HAMS Garments Ltd., from 2014 to 2016
GHG Emission Summery
Year Direct emission (stationery
fuel combustion)
Indirect emission (purchased
electricity consumption) Total in
tCO2e
2014 10631.2 139.0 10770.2
2015 12354.0 127.4 12481.3
2016 13522.3 31.9 13554.2
Production, Solid waste record, ETP outlet water quality & sources of air emission
The main products of HAMS Garments Ltd are finish garments & dyeing. However, dyeing
production is considered to calculate energy & water KPI and finish garments is considered
to calculate wastage jute KPI.
Year 2013 2014 2015 2016
Dyeing production (MT) 3588.92 3977.11 4052.69 4818.303
Finish Garments (MT) 1644 2509
Hazardous waste: Iron+Tin+Steel, Aluminum, Broken Glass, Broken tub-light, ETP Sludge,
Wastage oil, Chemical Drum, Medical waste, Poly and plastic & paper con.
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Non Hazardous waste: Jute, Rejected Yarn, Knitting yarn con, Cartoon, Paper, Cement Bag,
Salt Bag
Table: Solid waste record from 2015 to 2016
Year Non Hazardous waste
in MT
Hazardous waste
in MT
Total waste in
MT
2015 1132.3 62.7 1195
2016 1704.8 80 1784.8
Air emission inventory is presented in table-13. Air emission inventory is maintained
annually. The air emission test is conducted by third party annually for HAMS Garments Ltd.
There is no accredited body in Bangladesh for air emission test. That’s why third part air
emission test results are not presented in air emission inventory.
HAMS Garments Ltd. has an in-house ETP laboratory to analysis wastewater (before & after
treatment). Almost all kind of parameter like as COD, BOD, TSS, pH, TDS, MLSS, SV, SVI,
F/M can be analyzed by ETP laboratory
Target Setting & Action Plan
HAMS Garments Ltd. sets target to improve environmental performance as well as reduce
energy & water consumption. The concern authority review improvement against target
annually and take corrective action plan to achieve target.
Action plan to reduce energy consumption: Hot water/Condensate Recovery, Replacing
florescent light with LED light, Replacing conventional motor of sewing machine with
energy saving motor & Install Economizer on the steam boiler.
Action plan to reduce water consumption: Process Development, Rain Water Harvesting,
Using Water Efficient Equipment and Awareness & Monitoring.
Generation of wastage Jute reduction: The concern authority of HAMS Garments has planned
to produce baby items’ using wastage jute especially which is generated from cutting section.
Besides, wastage jute from sewing section can also be used to make home interior products.
The chemical management system will be formulated and it will work through Plan-Do-
Check-Act framework.
Conclusion
Table: Base year & reporting year Water & Energy KPI for per ton production
Year Base year 2015 2016 % reduction in 2016 Target year 2018
Water consumption 160.1 134.3 16.1 20%
Energy consumption 62.18 57 8.3 10%
From above table, it can be seen that the water & energy consumption for ton dyeing
production has been reduced significantly from 2015 to 2016. In percentage, the water &
energy consumption for per ton dyeing production are 16.1 and 8.3 respectively.
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Table of Contents
Executive Summery 2
Introduction 5
Water consumption Record 6
Energy Consumption & GHG emission Record 8
Dyeing Production, Solid waste record, ETP outlet water quality & sources of air emission 11
Target Setting & Action Plan 15
Conclusion 21
Acronyms and Abbreviations
EMS Environmental Management System
BMD Bangladesh Meteorological Department
GJ Giga Joule
MT Metric ton
GHG Green House Gas
ETP Effluent Treatment Plan
COD Chemical Oxygen Demand
BOD Biological Oxygen Demand
TDS Total Dissolved Solid
TSS Total Suspended Solid
MLSS Mixed Liquor Suspended Solid
SV Sludge Volume
SVI Sludge Volume Index
F/M Food to Microorganism
REB Rural Electrification Board
KWH Kilowatt Hour
LED Light Emitting Diode
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Chapter 1
Introduction
The garment industry has become the backbone of the economy of Bangladesh. About three
million people are involved with garment and textile industries. It is essential to promote
sustainability in this large industrial sector. When the world garment market and companies
are focusing on environment friendly products, the Bangladeshi garment and textile industries
are far beyond of it and it poses a risk of losing the world market. It is high time to adopt
special strategies and an approach towards sustainability.
Manufacturing environment friendly products in a sustainable way is the most important and
emerging issue at the present phase of industrialization. The main focus comprises not only to
the products quality sustainability but also it focuses on the manufacture processes including
raw material resources from cradle to grave. Nowadays many companies and organizations
focus on the environment friendly way of production. Sustainability of the garments industry
is also a burning issue, needed to adopt cleaner and improved technology and management
for better environment.
Despite the significant economic contribution of the textile industries in Bangladesh, it has
brought with it a range of environmental problems, mostly pollution of water resources of the
country, energy resources degradation/CO2 emission & eutrophication. Water is very
important resources in our ecology. In textile, water is an important component and without
this textile industry cannot be operated. Huge quantity of water is used specially in dyeing &
washing section. Water & energy resources are limited and these must be used reasonably
and responsibly.
HAMS Garments Ltd. has been working to adopt & implement various strategies and an
approach towards sustainability. As part of this work, water consumption, waste wastewater
generation and energy consumption are recorded. Besides, greenhouse gas emission and solid
waste inventory are maintained. The water & energy consumption, waste generation and
greenhouse gas emission are reviewed by HAMS Garments authority through sustainability
report which is drafted yearly. HAMS Garments authority sets target and define strategies to
reduce water & energy consumption as well as to improve environmental performance.
Based on water & energy consumption data of 2015, HAMS Garments authority sets three
years long target to improve environmental performance.
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Chapter 2
Water Consumption Record
HAMS Garments Ltd has installed water metering system to track & measure total water
consumption from natural resource and wastewater generation from manufacturing of
products. The activities within HAMS Garments Ltd are knitting, dyeing & finishing, cutting
& sewing. Most of the water is used for dyeing purpose. The source of water for HAMS
Garments Ltd is underground water. The main purpose of water metering system is; to track
& measure total water withdrawal from underground, total water consumption for production
& domestic purpose and the total wastewater generation from HAMS Garments Ltd.
The water consumption record for production purpose, water consumption in utility section
(boiler & generator), domestic use purpose and the wastewater generation record are
presented below:
Table-1: Water consumption record for production purpose, from 2013 to 2016
Soft water consumption in m3 for production-(Dyeing & Finishing)
Month/Year 2013 2014 2015 2016 January 47942 68059 55344 60436
February 45033 55311 52631 52824
March 52273 42642 56584 56550
April 52951 45280 46582 46558
May 54275 54307 49872 40934
June 54965 47921 55036 45044
July 62031 43378 42665 46054
August 47375 43104 58370 66751
September 62026 61115 48164 45549
October 39136 49578 63972 64279
November 66123 64363 58789 60411
December 65385 66238 60838 62056
Total 649515 641296 648847 647446
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Table-2: Water consumption record for domestic & utility purpose, from 2015 to 2016
Water consumption record in m3 for domestic purpose & utility section
Domestic purpose Utility section Month/Year 2015 2016 2015 2016
January 3171 3727 3029 3512
February 2640 3553 3260 4289
March 2296 3869 4618 4148
April 2768 4018 4021 5442
May 3604 4367 4699 5500
June 2984 4175 5411 5914
July 1822 2964 3502 5061
August 3213 4185 4566 6501
September 3293 2658 3034 4221
October 3817 3857 3963 5962
November 3804 3243 3718 5392
December 3925 3951 3698 5017
Total 37337 44567 47519 60959 Note: In 2013 & 2014, there was no separate water meter for domestic use and utility section. That’s why water
record for domestic & utility use is not available.
Table-3: Total water withdrawal from underground, from 2015 to 2016
Total water has been withdrawn by HAMS Garments Ltd from underground
Month/Year 2015 2016
January 61544 67675
February 58531 60666
March 63498 64567
April 53371 56018
May 58175 50801
June 63431 55133
July 47989 54079
August 66149 77437
September 54491 52428
October 71752 74098
November 66311 69046
December 68461 71024
Total 733703 752972
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Table-4: Total wastewater generation from HAMS Garments Ltd., from 2014 to 2016
Note: Water meter for ETP was not available in 2013
Chapter 3
Energy Consumption & GHG Emission Record
In textile, energy is an important component and without this textile industry cannot be
operated. Energy resources are limited and these must be used reasonably and responsibly.
HAMS Garments Ltd mainly uses natural gas & diesel for generating power & steam.
Table-5: Gas consumption record for generator
Waste Water generation (m3) Month/Year 2014 2015 2016
January 53254 39561 48287
February 44663 43210 38429
March 20484 45916 45076
April 21153 42579 34883
May 27070 42776 34495
June 27882 39431 40548
July 29962 37709 39808
August 30120 50613 60118
September 48415 39176 37081
October 37124 55437 54074
November 48933 51356 53671
December 50575 52425 55095
Total 439635 540189 541565
Gas Consumption (m3)- Generator
Month/Year 2013 2014 2015 2016
January 143622.22 158164.08 155290 198624.94
February 127280.05 154777.37 139910.57 199852.06
March 147483.25 157693.82 150750.86 197004.24
April 139462.51 160248.98 190085.51 203943.16
May 192648.75 165022.26 196971.95 204405.35
June 159865.51 164132.19 193750.75 228483.67
July 147979.74 140861.19 147582.13 166594.52
August 120270.49 158593.98 191855.56 227113.24
September 160414.48 131302.52 197797.44 167906.41
October 122432.1 146784.9 180177.68 218553.63
November 150532.89 167500.74 207325.83 210728.68
December 155635.15 156975.3 180847.75 210209.98
Total 1767627.14 1862057.33 2132346.03 2433419.88
Total in GJ 67876.9 71503.0 81882.1 93443.3
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Table-6: Gas consumption record for Boiler
Table-7: Diesel consumption record for standby generator
Natural gas, diesel & electricity from REB are recorded in cubic meter, litter & KWH
respectively. All of these energy units (m3, litter & KWH) converted to common unit GJ
using the following conversion factors:
Natural Gas: 38.4 MJ/Nm3
Diesel/fuel oil: 43.1 MJ/liter
Electricity (KWH): 3.6 MJ/KWH
Gas Consumption (m3)-Boiler
Month/Year 2013 2014 2015 2016
January 295160.23 328793.18 364402 432884.98
February 289151.75 344025.29 330490.57 420833.71
March 322175.17 261482.87 331879.16 386116.93
April 302161.71 333709.76 404584.38 384506.3
May 389447.13 337948.19 381630.26 375165.64
June 337928.01 328575.2 384476.05 419281.64
July 312273.39 274795.58 282917.22 300870
August 263870.52 252416.67 342124.05 405995.17
September 346552.2 300767.07 354952.37 300692.38
October 274805.67 287589.59 336182.18 410617.08
November 351983.45 354744.48 437339.37 428022.89
December 351299.24 330797.35 438552.37 422767.25
Total 3836808.47 3735645.23 4389529.98 4687753.97
Total in GJ 147333.4 143448.8 168558.0 180009.8
Diesel Consumption (Liter)-Generator
Month/Year 2013 2014 2015 2016
January 0 540 4962 392
February 312 60 1655 1366
March 548 345 4259 2196
April 0 4923 3211 895
May 552 5343 172 413
June 152 2851 333 370
July 0 1995 1626 3761
August 0 2429 185 987
September 205 3768 375 930
October 254 2644 0 8533
November 1068 822 625 7980
December 0 346 830 4237
Total 3091 26066 18233 32060
Total in GJ 133.2 1123.4 785.8 1381.8
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Table-8: Purchase electricity consumption record from REB
Table-9: Total energy consumption record in GJ of HAMS Garments Ltd., from 2013 to 2016
Year 2013 2014 2015 2016
Energy in GJ 215473.2 216972.9 252011 275034
The most of the energy used in dyeing section approximately 70% of total energy, around
20% of total energy used in garments building and rest of the total energy used in others
sections.
Table-10: GHG emission record from HAMS Garments Ltd., from 2014 to 2016
GHG Emission Summery
Year Direct emission (stationery
fuel combustion)
Indirect emission (purchased
electricity consumption) Total in
tCO2e
2014 10631.2 139.0 10770.2
2015 12354.0 127.4 12481.3
2016 13522.3 31.9 13554.2
Electricity Consumption (KWH)
REB (Rural Electrification Board)
Month/Year 2013 2014 2015 2016
January 795 1855 43725 265
February 1325 530 51675 17755
March 1325 4505 67840 530
April 2650 23585 23055 2650
May 2650 24910 1325 1325
June 1590 25175 265 530
July 795 37895 11395 12985
August 10600 30740 4770 530
September 795 32595 11395 11130
October 9805 31800 530 530
November 2650 16960 1325 4770
December 1060 18815 795 2385
Total 36040 249365 218095 55385
Total in GJ 129.7 897.7 785.1 199.4
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Chapter 4
Production, Solid waste record, ETP outlet water quality & sources of air emission
The main products of HAMS Garments Ltd are finish garments & dyeing. However, dyeing
production is considered to calculate energy & water KPI and finish garments is considered
to calculate wastage jute KPI.
Table-11: Dyeing production record from 2013 to 2016
Solid waste:
Waste is any substance or object which is discarded, intended to be discarded or is required to
be discarded. Waste can include expired raw materials generated from a process for which
there is no further use on-site, expired finished products, process or non-process by-products,
customer returns, redundant equipment, etc.
"A hazardous waste is a waste that could cause harm to public health and/or the environment
because of its chemical, physical or biological characteristics (e.g., it is flammable, explosive,
toxic, radioactive, or infectious). Hazardous wastes that is dangerous or potentially harmful to
our health or the environment. Hazardous wastes can be liquids, solids, gases, or sludge.
They can be discarded commercial products, like cleaning fluids or pesticides, or the by-
products of manufacturing processes. (The U.S. Environmental Protection Agency).
Table-12 presents the amount of solid waste including hazardous & non-hazardous was
generated from HAMS Garments Ltd.
Dyeing production (kg)
Month name Fabric
Year 2013 2014 2015 2016
January 252613 330294 319097 426025
February 300134 242658 340074 324081
March 330150 375027 350330 375630
April 300074 380013 350219 316457
May 317282 378144 412211 379017
June 314019 358231 301497 395511
July 373415 266413 215163 318432
August 239759 256298 304137 460945
September 307878 383055 280308 306655
October 248050 286025 385225 467695
November 303800 358850 369027 504653
December 301746 362101 425401 543202
Total (kg) 3588920 3977109 4052689 4818303
Total in MT 3588.92 3977.11 4052.69 4818.303
Finish Garments in pcs 10959563 16728104
Finish Garments in MT 1644 2509
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Table-12: Solid waste record from 2015 to 2016
Year Non Hazardous waste
in MT
Hazardous waste
in MT Total Solid
waste in MT
2015 1132.3 62.7 1195
2016 1704.8 80 1784.8
Hazardous waste: Iron+Tin+Steel, Aluminum, Broken Glass, Broken tub-light, ETP Sludge,
Wastage oil, Chemical Drum, Medical waste, Poly and plastic & paper con.
Non Hazardous waste: Jute, Rejected Yarn, Knitting yarn con, Cartoon, Paper, Cement Bag,
Salt Bag
Air Emission Inventory:
Air emission inventory is presented in table-13. Air emission inventory is maintained
annually. The air emission test is conducted by third party annually for HAMS Garments Ltd.
There is no accredited body in Bangladesh for air emission test. That’s why third part air
emission test results are not presented in air emission inventory.
Table-13: Air emission Inventory
S.l.No EMISSION POINT NAME OF POLLUTANTSOURCE/
EQUIPMENT
EMISSION
AMOUNT
(AND UNITS)
LEGAL EMISSION
LIMIT(DoE)
MONITORING
FREQUENCY
1 Gas Generator NOX Generator N/A200 (mg/Nm3),
DoE StandardAnnual
2 Gas Generator Sox Generator N/A0.14 ppm 24 hrs &
0.03 ppm annualAnnual
3 Gas Generator CO Generator N/A9 ppm 8 hrs & 35
ppm 1 hrAnnual
4 Diesel Generator NOX Generator N/A 0.053 ppm annual Annual
5 Diesel Generator SOx Generator N/A
150 mg/Nm3 24
hrs & 50 mg/Nm3
annual
Annual
6 Diesel Generator CO Generator N/A
65 mg/Nm3 24 hrs
& 15 mg/Nm3
annual
Annual
7 EGB Boiler SOx Boiler N/A 0.12 ppm 1 hr &
0.08 ppm 8 hrs Annual
8 EGB Boiler NOX Boiler N/A 0.5 mg/Nm3
annual Annual
9 EGB Boiler CO Boiler N/A NYS Annual
10 Gas boiler SOx Boiler N/A200 (mg/Nm3),
DoE StandardAnnual
11 Gas boiler NOx Boiler N/A0.14 ppm 24 hrs &
0.03 ppm annualAnnual
12 Gas boiler CO Boiler N/A9 ppm 8 hrs & 35
ppm 1 hrAnnual
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In-house laboratory wastewater test report:
HAMS Garments Ltd. has an in-house ETP laboratory to analysis wastewater (before & after
treatment). Almost all kind of parameter like as COD, BOD, TSS, pH, TDS, MLSS, SV, SVI,
F/M can be analyzed by ETP laboratory. The activity of this laboratory was started from
March, 2016. In 2016 around 32 times laboratory analysis were carried out. In table-14, only
ETP outlet water test results are presented.
Table-14: ETP outlet water quality test report (In house laboratory)
Date COD in
ppm
BOD in
ppm
TSS in ppm pH
23/03/16 148 35 7.64
24/03/16 140 7.4
29/03/16 81 25 7.35
6/4/2016 159 7.46
12/4/2016 142 25 7.28
24/04/16 70 16 7.46
24/04/16 180 30 7.56
28/04/16 142 30 7.5
8/5/2016 53 20 7.44
28/5/16 72 30 7.55
12/6/2016 67 30 7.6
19/06/16 61 25 7.34
25/06/16 87 20 7.5
21/07/16 189 45 7.4
26/07/16 195 35 7.4
4/8/2016 111 25 7.4
14/08/16 45 20 7.4
28/08/16 132 7.34
4/9/2016 69 22 7.35
21/09/16 82 17 7.25
24/09/16 129 28 7.43
25/09/16 146 7.45
9/10/2016 178 25 7.2
19/10/2016 180 22 25 7.7
20/10/2016 170 33 7.5
26/10/2016 175 38 7.28
17/11/2016 140 20 20 7.5
22/11/2016 198 28 22 7.5
27/11/2016 160 40 20 7.3
7/12/2016 200 30 9 8.2
14/12/2016 174 18 30 7.47
25/12/16 139 26 25 7.96
Average 132 27
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Chapter 5
Target Setting & Action Plan
HAMS Garments Ltd. sets target to improve environmental performance as well as reduce
energy & water consumption. The concern authority review improvement against target
annually and take corrective action plan to achieve target.
Energy
Target Name 10% energy consumption reduction for
per ton dyeing production
Target Type Normalized
Base year 2015
Target Start date 01/01/2016
Target End Year 31/12/2018
% Reduction from base year 8.3
Metric for Normalized targets per ton of fabric
Base year consumption amount 62.18 GJ
The current reporting period's normalized
energy consumption amount
57 GJ
Water
Target Name 20% Water consumption reduction for
per dyeing production
Target Type Normalized
Base year 2015
Target Start date 01/01/2016
Target End Year 31/12/2018
% Reduction from base year 16.1
Metric for Normalized targets per ton of fabric
Base year consumption amount 160.1 m3
The current reporting period's normalized
energy consumption amount
134.3 m3
Solid waste
Target Name 10% wastage Jute reduction for per ton
finish garments
Target Type Normalized
Base year 2016
Target Start date 01/01/2017
Target End Year 31/12/2018
% Reduction from base year N/A
Metric for Normalized targets per ton finish garments
Base year consumption amount 596 (kg)
The current reporting period's normalized
energy consumption amount
N/A
Chemical management
Target Name Achieve 80% score in chemicals
management performance in self-
assessment module
Target Type Absolute
15
Base year 2016
Target Start date 01/01/2017
Target End Year 31/12/2018
% increase chemicals management
Performance score from base year
N/A
Metric for Absolute targets Total score in self-assessment module
Base year score 37%
The current reporting period's score N/A
Action Plan:
Energy:
Hot water/Condensate Recovery:
Projection Time: 50% condensate already recovered from 2015 to 2016, 30% more
condensate will be recovered by 2017-2018.
If 1 ton/h of steam is supplied to equipment for a heating process, then the same amount of
condensate (1 ton/h) needs to be discharged from the equipment. Condensate recovery is a
process to reuse the water and sensible heat contained in the discharged condensate.
Recovering condensate instead of throwing it away can lead to significant savings of energy,
chemical treatment and make-up water. Reusing hot condensate can lead to considerable
savings in terms of energy and water resources, as well as improve working conditions and
reduce your plant's carbon footprint. Condensate contains a significant amount of sensible
heat that can account for about 10% to 30% of the initial heat energy contained in the steam.
Feeding the boiler with high-temperature condensate can maximize boiler output because less
heat energy is required to turn water into steam. When efficiently recovered and reused, it can
even be possible to reduce boiler fuel needs by up to 10 to 20%.
Theoretically one m3 water is required to produce one ton steam. HAMS Garments Ltd has a
NG boiler with the capacity of 7.7 ton per hour and a waste heat boiler with the capacity of 1
ton/h. Presently these boilers are being operated with at 85% load of their capacity. Steam is
used mainly in dyeing, washing, drying and finishing in addition to garments (ironing). At
present, about 50% of the steam condensate is returned to the steam boiler. Condensed &
Flash stream from dye & garments recovered to feed water tank that use to pre heat the boiler
again up to 90-920c.
Replacing florescent light with LED light:
Projection Time: Around 80% of florescent light in HAMS Garments Ltd. were replaced with
LED in 2015 to 2016.
In 2016 around 990 LED light were inserted in Garments building. It is assume that
approximately 5% energy can be saved by replacing florescent light with LED.
16
Replacing conventional motor of sewing machine with energy saving motor:
Projection time: 2016
Approximately 90% conventional clutch motor of sewing machine replaced with energy
saving amida direct drive servo motor. The total sewing machine in T-shirt & undergarments
section is 1781. In 2016, conventional clutch motor of around 1631 sewing machine were
replaced with energy saving amida direct drive servo motor. It is assume that around 25%
less energy is required by amida direct drive servo motor compare to conventional clutch
motor.
Install Economizer on the steam boiler:
Projection Time: 2017
Inserting an economizer in the flue gas outlet of the steam boilers as to preheat the boiler feed
water would save about 2.7% on the fuel consumption for steam production. Economizer can
be used for both NG and fuel oil fired boilers.
Upgrade generator monitoring to electrical power management control system
Projection Time: 2017 to 2018
The present generator monitoring provides too little information for monitoring their
performance. Fortunately a better generator monitoring system is available. However even
this system can be improved and extended as to include real-time diesel consumption and
overall generator efficiency along with the complementing power consumption from the grid.
By installing an electricity measuring system for generator and by upgrading this monitoring
system to calculate effective efficiency at varying load and adding automatic modulating
controls a true electrical power management system can be realized automatically control all
generators which switches the generators on/off according to demand and optimizes the
production of each generators as to achieve maximum the overall efficiency while
minimizing the total cost of power consumption including grid and stand-by diesel
generators.
Water:
Process Development
Projection Time: Already implemented from January, 2016
Water consumption in dyeing process can be reduced significantly by developing/modifying
dyeing process or by selecting alternative dyeing process. Fill & Drop process is
advantageous than the rinse/MIR process regarding water consumption. However it is more
time consuming and by overflow/MIR Process there will be almost double consumption of
water. So the subtitle is that Fill & Drop process will give us low consumption of water but it
will also decrease our productivity. It can also effect on quality and costing to some extent
On the other hand rinse/MIR process will consume more water but it can meet the required
17
production and quality target. So it has to say, we want to maintain our productivity with
quality and also water consumption in our range the co-ordination of both process is obvious.
Table-13: Water consumption comparison between Fill & Drop Process and MIR process
(Dark color, at 80% loading)
Fill & Drop Process Rinse/MIR Process
PROCESS WATER(LTR) PROCESS WATER(LTR)
SCOURING 6 SCOURING 6
WASH (FILL & DROP) WASH
NORMAL HOT 3.5 NORMAL HOT 3.5
WASH (FILL & DROP) 3.5×2=7 WASH 12
ACID ,PC,ENZYME 2.5 ACID ,PC,ENZYME 2
WASH (FILL & DROP) 3.5 WASH 10
LEVELLING 3.5 LEVELLING 3.5
COLOR COLOR
SODA SODA
CAUSTIC CAUSTIC
BD WASH(MIR) 10 BD WASH 10
BD WASH(FILL & DROP) BD WASH
NORMAL HOT 3.5 NORMAL HOT 3.5
WASH (FILL & DROP) 3.5X3=10.5 WASH 8+8=16
BD ACID 3.5 BD ACID 3.5
WASH (FILL & DROP) 3.5 WASH 3.5
SOAPING 3.5 SOAPING 3.5
WASH (FILL & DROP) 3.5X3=10.5 WASH 8+8=16
SOFTENER SOFTENER
WASH (FILL & DROP) WASH
Water Con. (Lt/Kg) 71 Water Con. (Lt/Kg) 93
Rain Water Harvesting
Projection Time: March, 2017 to December, 2018
HAMS Garments Ltd has a plan for rainwater harvesting on roof top area of the shads &
buildings. Table-3 presents the roof top area of the shads & buildings with the annual volume
of rainfall. From figure-1, it can be seen that the lowest annual rainfall is 4.4 mm in January
and the maximum annual rainfall is 388.5 mm in July. In average, at Dhaka & Gazipur
region, the annual rainfall is 1960 mm from 2001 to 2015.
18
Figure-1: Monthly averages of Rainfall & Humidity data at the Dhaka & Gazipur region
(From Dhaka BMD Station), 2001-2015. Source: Bangladesh Meteorological Department
Table-14: Roof top area of the shads & buildings with the yearly volume of rainfall
Building/shad Area in m2 Annual average
rainfall in mm
Volume of rainfall
(Annual) in m3
Garments Building 2787.09
1960
5462
Dyeing shad 3753.28 7356
Knitting shad 802.5 1572
Chemical store 1672.25 3277
Central warehouse 1170.57 2294
New Building-1 1672.25 3277
New Building-2 557.41 1092
Total 12415.35 24330
http://www.calctool.org/CALC/other/default/rainfall(this tool use to convert rainfall in mm to
rainfall in m3 considering roof top area)
From table-14 it can be seen that, HAMS Garments Ltd can use approximately 24330 m3
water annually from rainwater harvesting instead of using from ground water. According to
figure-1, the maximum possible rainfall is 388 mm (4817 m3 for area of 12415.35 m
2) in July
throughout the year. The daily soft water consumption specially for dyeing section is 2000
m3.
Using Water Efficient Equipment
Projection time: Already Implemented in 2015-2016.
Water consumption for production purpose can be saved by replacing outdated equipment
with modern machines which operate at lower liquor ratio.
Example-1: A low liquor ratio Sclavos Athena3 dyeing machine, with a capacity of 2 tons
per day, had been installed in the dyehouse, which is expected to save 996 m3 water monthly
compared to the existing dyeing machines.
Example-2: HAMS Garments Ltd has a biological ETP with the capacity of 2000 m3 per
day. Continuous aeration is necessary for biological ETP and aeration is provided by blower.
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Two blowers were running simultaneously in HAMS Garments ETP and these blowers were
needed to be cold by supplying soft water. For this purpose, around 35 m3 water per day was
needed. These blowers have been replaced with a modern turbo blower on November, 2016.
It should be mentioned here that, this turbo blower don’t needs soft water for cooling
purpose. HAMS Garments ltd has saved 35m3/day
water by installing a modern turbo blower.
Table-15: water saved by using water efficient equipment
Water Efficient
Equipment
Monthly save in
m3
Yearly save in m3 Total Yearly
save in m3
Low liquor ratio Sclavos
Athena3 dyeing machine 996 11952
24552
Modern turbo blower 1050 12600
From table-15 it can be seen that HAMS Garments Ltd has been reduced water consumption
around 24552 m3 yearly by using water efficient equipment. Besides, HAMS Garments Ltd
has planned to use more water efficient equipment especially low liquor dyeing machine
within next two years.
Awareness & Monitoring
Projection time: January, 2017 to April, 2017
The significant amount of water consumption for dyeing & washing section can be saved by
monitoring & creating awareness.
Turn off Running Taps and Hoses
This simple procedure can result in substantial savings. People are often unaware of the cost
of leaving taps and hoses running. They are more likely to turn off running taps and hoses if
they are made aware of the annual cost of waste. Meanwhile, fixing hand triggers to hoses is
a simple way of reducing water use and saving money.
Turn off Water when Machines are not running.
Encourage workers to turn off machines and water during breaks and at the end of the day.
Avoid circulating cooling water when machines are not in use. The concern department of
HAMS Garments Ltd has been working to formulate & implement an integrated
Environmental Management System (EMS). A relevant program for creating awareness &
monitoring regarding water consumption will be included of that EMS.
Generation of wastage Jute reduction:
The most of the solid waste in HAMS Garments is wastage jute. The wastage jute mainly
generate from cutting & sewing section. Besides, considerable amount of wastage jute is
generate from rejected yearn & rejected garments. The concern authority of HAMS Garments
has planned to produce baby items’ using wastage jute especially which is generated from
20
cutting section and wastage jute from sewing section can also be used to make home interior
products. The baby items (Garments) and home interior products which are produced using
wastage jute will not for commercial purpose. These will be donated to factory’s worker on
occasional day. Besides, HAMS Garments authority has planned to use modern cutting
machine which will generates less wastage jute compare to conventional cutting machine.
Improve chemicals management performance:
The concern authority of HAMS Garments Ltd. committed to:
Continual improvement of chemical management performance
Expand win of economic, environmental, safety & health and organizational benefits
through implementing systematic management of chemicals
Complying with national legislation and conforming to emerging customer
requirements and international standards on management of chemicals
strengthening in-house competence of personnel in companies (workers, middle
management), integrating CM training into in-house training units
enabling EHS managers/officers and company personnel concerned with handling of
chemicals in textile companies to improve the condition of chemical management in
the factory
The chemical management system will be formulated and it will work through Plan-Do-
Check-Act framework. The following jobs will be conducted through Plan-Do-Check-Act
framework to establish an appropriate chemical management system:
Maintaining legal register including National and other laws and regulations
Systematically identify and document chemicals used and stored
Material flow accounting; Process flow diagram, Chemical trajectory & NPO
identification
Maintaining Chemical inventory, Chemical risk analysis and Hazard & risk mapping
Chemical risk management action; Training, Document Development, Document and
Record Control,
Chemical Management Work Practices & Emergency Procedures; Exposure control
measures, Safety data sheet management(procedure for making SDS available),
Chemical handling( procedure for SOP development, format), Chemical storage in
well design store, Chemical transportation, Chemical use –Regular and optimization,
Personal protective equipment (procedures for selection, use, maintenance),
Laboratory practices, Maintenance and housekeeping, Waste and disposal.
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Chapter 6
Conclusion
The total dyeing production (MT), water (m3) & energy (GJ) consumption and wastewater
(m3) generation in 2015 and 2016 of HAMS Garments Ltd. are presented in table-16.
Table-16: Total dyeing production, water & energy consumption and wastewater generation
Year 2015 2016
Dyeing production(MT) 4052.7 4818.3
Water consumption(m3) 648847 647446
Waste water(m3) 540189 541565
Energy consumption(GJ) 252011 275034.3
Figure-2: presents the water & energy consumption and wastewater generation for per ton
dyeing production (from 2015 to 2016)
Table-17: Base year & reporting year Water & Energy KPI for per ton production
Year Base year
2015
2016 % reduction in
2016
Target year
2018
Water consumption (m3) 160.1 134.3 16.1 20%
Energy consumption (GJ) 62.18 57 8.3 10%
From table-17, it can be seen that the water & energy consumption for ton dyeing production
has been reduced significantly from 2015 to 2016. In percentage, the water & energy
consumption for per ton dyeing production are 16.1 and 8.3 respectively.
………………
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