Monitoring Team:

# Name
1
2
3
4
5
6

Resource
Visit Monitoring Sl. No. Factory name Address
Description Month:

Lamapara, Kutubpur,
1st Followup 1 Rupashi Knitwear Ltd.
Fatullah,Narayanjang

2nd Followup 2
3rd Followup 3

4th Followup 4

5th Followup 5

6th Followup 6
 BCAS

FACTORY CP TEAM
Department Designation Role

Wet processing capacity/

Contact person and details Type
month

Md. Nasir Uddin, AGM - HRD , Cell - knit dyeing & garments
+8801730041189, E-mail: 625
washing
nasir.uddin@rupashigroup.com
 Contact No. Mail ID

Wet processing
production
(ton / month)
Number of workers Brands
Service Provider Other Brands
in wet process nomination

570 BCAS indetects 731

BCAS
BCAS

BCAS

BCAS

BCAS

Average 731

Annual 8,772
 Monthly Consumption :

Natural Gas (NG) in Nm including correction factor (ref. bills)

Unutilised hours
of finishing
machines.
Ground Water Softened Water Total Total Process Natural Gas
[m] [m] chemical water [Nm]
(Heating +
power)

87,636 594 71,483 658,567

 87,636 71,483 658,567

1,051,632 857,796 7,902,804

mption : Environmental Impact :

orrection factor (ref. bills) TDS = total dissolved solids

(salt), DS = dry solids
Nat

Diesel Steam Electricity ETP outlet GHG Ground

[MWh] volume as CO2 Water
[liter] [tons] (Generator+Grid) [m] (calc.)
[tons] [m3/ton]

4,666 10,025 518 54,225 21.34 119.89

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10025 518 54225 21

120300 6216 650700 256

119.8850889
 Key Performance Indicators (KPI's) :

calculated per ton of fabric produced

Natural Gas (NG) in Nm including correction factor (ref. bills)

Process Natural Gas Diesel Steam Electrical ETP outlet

Water (total) (total) volume
[Nm/ton] [liter] [ton/ton] [m/ton]
[m3/ton] [MWh/ton]

97.7879617 900.91 6.38 13.71409029 0.7086183311 74.179206566

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#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

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97.7879617 900.9124487004 13.71409029 0.7086183311 74.179206566

 GHG
as CO2
(calc.)
[ton/ton]

0.0291928865

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0.0291928865
 ACTION PLAN ON CLEANER PRODUCTION ASSESSMENT (CPA) RECOMMENDATIONS

FACTORY Rupashi knitwear ltd.

ADDRESS Lamapara, Kutubpur, Fatullah,Narayanjang

TYPE OF FACTORY (WET PROCESS) knit dyeing & garments washing
ASSESSMENT DONE ON
DE-BRIEFING DONE ON
LOCAL CONSULTANT BCAS
BRAND NAME

FACTORY CP TEAM
# Name Department Designation
1 Md. Nasir uddin AGM (HRD)
2 Mr. Ratan Ghosh GM, Maintenance
3 Md. Ohidul Islam Manager, Compliance
Mr. Shujon Kumar Mandol
4 AGM (Washing)
5 Mr. Emdadul Haque DGM (Dyeing)

FACTORY BASE LINE INFORMATIONS

ANNUAL CONSUMPTION (BASED ON BASIC CP ASSESSMENT)
# Parameter Unit Annual consumption
1 Water m3 1,051,640
2 Natural gas m3 7,902,835
3 Diesel ltrs 56,000
4 Steam ton 120,300
5 Power MWh 6,218,456.00

Present Baseline KPIs (Per kg of material processed)

Av Monthly prod
Ground Water m3/ton 119.89
Process Water m3/ton 97.78
Chemicals
Power
NG (Total)
NG (Process)
Steam

RESOURCE COST (BASED ON ASSESSMENT)

# Resource unit Cost
1 Water cost BDT/m3
2 Power cost BDT/kWh
3 Steam cost BDT/ton
4 Compressed air cost BDT/m3
5 Natural gas cost (generator) BDT/m3
 6 Natural gas cost (boiler) BDT/m3

General info:
Average working day/year for wet process
Wet process man power
Total number of employees (if different from above)
Capacity of the factory (Ton/ month)
Info gathered from the year
1 USD = BDT.
MENDATIONS

Role
Team Leader
Utility Coordinator
Compliance Coordinator

Washing section coordinator

Dyeing section coordinator

Annual Cost, USD

175,274
682,885
46,666
 Area Process

# Assessment Findings Related picture before

area

1 During the assessment, it was observed that

there was no water flow meter present in the
factory.

2 During the assessment, it was observed that

the factory has no water consumption
monitoring system present. As a result,
excessive water is been used and also lots of
water wastage is occurring.

3 During the assessment, few water leakages

were observed due to damaged water valves
4 During the assessment, it was observed that
and fittings. If all the leakages are added up,
wet floors are kept unattended. It is assumed
considerable amount of water is being
that about 5% of the total consumed water is
wasted.
wasted for poor housekeeping.

5 During the assessment period, it was

observed that none of the washing machines
have functional water level scale or any
scope to measure the water usage. As a
result, monitoring liquor ratio or water
usage is not possible.
 6 During the assessment period, it was
observed that some gauges were in working
condition while others were either
malfunctioning or completely out of order.
Calibration of different gauges is not carried
out at present.

7 During assessment, it was observed that

Process
chemicals were measured by volume before
dosing, though the recipe states chemicals
dosing by mass. It can be assumed that
more than 5% excess chemicals are wasted
due to this.

8 During the assessment period, it was

observed that water from open hose pipes
are been used for various cleaning purposes.
Using open hose pipes can be a cause of
water wastage.

9 During the assessment, it was noticed that

the operators were individual tanks to heat
water for sample washing.

10 During the assessment, it was noticed that

the continuous wash is being used for
rinsing operation.

11 During the assessment, it was observed that

the hot wastewater was drained without
recovering its heat.

12 There is no recovery/reuse of hot cooling

water. A significant amount of warm water
is being drained in the sewage and this can
be utilized in further processing.

AREA UTILITY
# Assessment Findings Related picture before
area

13 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.

14 T8-36w tube lights with magnetic ballast

are being used. The total number of T8 tube
lights was found to be 1200 pcs at the
washing floor and dyeing floor.

15 It was observed that VFDs are not installed

on compressor which is used as prime.

16 It was observed that servo voltage stabilizer

is not present onlighting load circuit, which
is inefficient way to use lighting load.

17 It was observed that Rupashi 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.

18 The factory collects around 40% condensate

from its dyeing section by gravity return &
rest of the condensate water from steam
has been drained into the atmosphere.
Utility
19 No schedule for combustion analysis of the
boiler was found. From the stack analysis of
boiler 10.8 TPH, oxygen content was found
around 7.2 %, which is high. The percentage
of excess air in the boiler was found around
57%, while it should be at a range of 15-
20 Feed
20%. water tank insulation is not
satisfactory.
21 It has been observed that significant amount
of steam pipes and steam valves are un-
insulated. Also steam leakages and faulty
steam trap are found at multiple points.

22 It has been observed that significant amount

of heat is released to the environment with
boiler exhaust.

23 It has been observed that Gas generator flue

gas is directly thrown into the atmosphere
without any heat recovery.

24 It has been observed that compressed air is

used for machine cleaning and open pipes
are used at 10 cleaning points.

Total Recommendations
Accepted Recommendation
Not Accepted Recommendations
Implemented Recommendations
 Total Recommendations Suggested
Total Recommendations Accepted Initially
Recommendations Implementated
Recommendations in implementation/planning/pre-planning stage
Recommendation Not Implemented
Recommendations not accepted
% Recommendation implemented (% of Total)

Total Investment
Total Savings (Yearly)

ACTION PLAN ON CLEANER PRODUCTION ASSESSMENT

CP ASSESSMENT OUTCOMES AND ACTION

Related picture after Recommendations

Installation of Water Flow

Meters

Regular Monitoring For Water

Consumption

Proper Maintenance of Water

Valves, Fittings and Pipes to
Maintaining Good Housekeeping
Reduce Water Leakages
in the Wet Process Section

Installation of Water Level Scale

in Washing Machines
 Calibration of different gauges
and meters in the washing area

Optimization of chemical dosing

by using proper method

Installation of Water Trigger

Nozzles for Cleaning Purpose in
Washing/Dyeing Areas

Use of a common dedicated

sample washing facility for each
of the dyeing house units

Promoting Block wash in place of

Continuous wash

Heat recovery from process hot

wastewater

Heat recovery from cooling water

of dyeing machines

ACTION PLAN ON CLEANER PRODUCTION ASSESSMENT

CP ASSESSMENT OUTCOMES AND ACTION

Related picture after Recommendations

Installation of energy meters to

monitor specific energy
consumption to each department

Installation of energy efficient

lights

Installation of Variable frequency

drives on compressor

Installation of servo voltage

stabilizer to lighting load circuit

Proactive Maintenance of
Electrical Systems

Upgradation of current
condensate recovery system

Proper monitoring of boiler

combustion efficiency and burner
tuning

Minimizing heat loss by proper

insulation of the feed water tank
 Minimizing heat loss by proper
insulation of bare surface, pipes,
valves and correction of steam
leakages and traps

Install boiler economizer to

recover heat from boiler flue gas

Recovery heat from generator

exhaust by using waste heat
recovery boiler

Reducing compressed air

consumption by using air nozzles
instead of open pipes

24
0%
0%
0%
Accepted Initially 20
mentated 10
ementation/planning/pre-planning stage -15
1
4
lemented (% of Total) #DIV/0!

$ - Total Investment
$ -

ANER PRODUCTION ASSESSMENT (CPA) RECOMMENDATIONS

CP ASSESSMENT OUTCOMES AND ACTION PLAN

Detail actions Projected environmental Estimated
benefits/year Investment, USD

It is recommended that the factory should

install water flow meters for the ground water .Water saving possible
consumption and process inlet and ETP outlet. NG saving possible 965
GHG emission reduction possible

It is recommended that the factory should

have well planned water monitoring system.
Water saving possible
NG saving possible
GHG emission reduction
possible
Water saving:73,615 m3/year
It is recommended that on the occurrence of NG saving:20,393 Nm3/year
minimum
water leakages it should be immediately GHG emission reduction:38.52
It is recommended that good housekeeping ton/year
repaired. Monthly inspection of the water
practices should be maintained in the wet Water saving: 52,582 m3/year
valves and fittings should be introduced to
section. Proper drainage system should be NG saving: 14,567 Nm3/year
proactive maintenance checklist.
made so that water wont get clogged in the GHG emission reduction: 27.52
working area. ton/year

It is recommended that all working washing

machines should have water level scale or any
digital measuring system so that the water
usage can be monitored. It can be assumed
that 5% of water wastage can be reduced by
proper water measuring.
Water saving: 42,890 m3/year
NG saving: 11,882 Nm3/year
120
GHG emission reduction: 22.44
ton/year
 It is recommended to calibrate all the gauges.
All gauges (temperature, pressure and speed)
need to be properly calibrated according to the
prescribed calibration plan at specified Process Improvement
intervals.

Chemicals should be measured by mass using

the available electronic balance before dosing.
Significant savings in chemical
consumption

It is recommended that open hose pipes

should be used with water trigger nozzles. Water saving: 13,140 m3/year
Water trigger nozzles can control the water NG saving: 3,640 Nm3/year
288
flow as well as reduce water wastage. GHG emission reduction: 6.88
ton/year

A dedicated washing facility should be in Water saving: 9,744 m3/year

place for each of the dyeing house units. NG saving: 87,360 Nm3/year 3,077
Significant savings can be achieved using a GHG emission reduction: 165 (for 4 tanks)
common dedicated washing facility. ton/year
It is recommended that the practice of using Water saving possible
continuous wash should be replaced by block NG saving possible
wash. This would reduce water wastage as GHG emission reduction
well as energy wastage. possible
Energy may be recovered from high
temperature wastewater of dyeing machines to
heat process water or for heating boiler make-
up water. A heat exchanger and associated NG saving : 475,083 m3/year
equipment would be required for this. This GHG emission reduction: 898 30,641
will reduce ETP load giving significant ton/year
savings.

Hot cooling water discharged from dyeing

machines may be sent to a hot water module Water saving: 27,615 m3/year
for further use in the processes instead of NG saving : 128,668 Nm3/year
6,410
discharging to the drain. GHG emission reduction : 243
ton/year

ANER PRODUCTION ASSESSMENT (CPA) RECOMMENDATIONS

CP ASSESSMENT OUTCOMES AND ACTION PLAN

Detail actions Projected environmental Estimated
benefits/year Investment, USD

It is recommended to install energy meter

gradually at different sections like washing,
dyeing, finishing, ETP and utility to measure Water saving possible
specific power consumption and record the NG saving possible
250
readings on continual basis to calculate the GHG emission reduction
specific energy consumption. possible

It is recommended to replace current fixtures

with T5-28w lights to improve energy Power saving : 280,051
efficiency of lighting system. Higherintensity kWh/year
light output than T8 lamps and at least 30% NG saving : 96,618 m3/year 10,769
energy savings are possible. GHG emission reduction : 183
tons/year

It is recommended that VFD be installed on Power saving : 142,239

compressor and boiler FD fan motor. kWh/year
Installation of VFDs on that variable load will NG saving : 49,073 m3/year 9,318
give good energy savings through increased GHG emission reduction : 42.5
motor efficiency and these will also reduce tons/year
regular maintenance costs.
It is recommended that servo voltage
stabilizer be installed to the lighting load Power saving : 47,977 kWh/year
circuit. Installation of SVS on that lighting NG saving : 16,552 m3/year
5,777
load will give good energy savings through GHG emission reduction : 31
increased load efficiency&lifetime; these will tons/year
also reduce regular maintenance costs.
It is recommended to follow proactive
maintenance schedule to prevent unwanted
shutdown of machines and to prevent
electrical fire hazard in the factory.

It is recommended to upgrade the current

condensate recovery system and installed a NG saving : 486,001
pressurized condensate recovery system to m3/year
5,000
recover all the condensate and flash steam GHG emission reduction : 918
from process and garments section. It is tons/year
estimated that around 60% condensate can be
Burner analysis and tuning should be carried
easily recovered with minimum effort NG saving : 106,605
out at all the firing modes. Boiler efficiency
should be monitored and burners need to be m3/year
1,538
tuned at least once every 3 months. Proper GHG emission reduction : 201
maintenance and burner tuning can give 2-5% tons/year
fuel saving.
Proper insulation of the feed water tank will NG saving : 22,028
reduce energy consumption and maintain the m3/year
desired temperature. 1,625
GHG emission reduction : 41
tons/year
Proper insulation of all un-insulated steam
lines (approx. 80 feet), valves (41 nos.), repair NG saving : 74,871
of steam leakage & steam traps will ensure m3/year
1,456
steam loss saving of around 918 ton/year. GHG emission reduction : 141
tons/year

There is a thumb rule that for each 22C

decrease in boiler flue will increase 1%
efficiency of the boiler. From flue gas NG saving : 106,605
analysis, it has been observed that at least 2% m3/year
15,400
to 3% efficiency can be increased by GHG emission reduction : 201
installing Economizer tons/year

There are 3 gas generators in Rupashi. A

common WHRB of 1.8 ton/h can be installed
for the generators. NG saving : 792,000
m3/year
80,000
GHG emission reduction : 1,496
tons/year

If Air nozzles are used instead of open pipes,

significant amount of compressed air can be NG saving : 21,083
saved and hence, less energy would be m3/year
200
required. Using the suitable type of air nozzles GHG emission reduction : 39
are subject to the application. tons/year
 Total Savings for Process (Yearly) Total Savings for Utility (Yea
Water savings 0 m3 Water savings
NG savings - m3 NG savings
Electricity Savings - kWh Electricity Savings
Steam savings - Ton Steam savings
GHG - Ton GHG

Total Investment

Projected annual Accept (Y/N) Status of the Directly Responsible Timeframe for
benefits, USD Recommendations Person Individual(DRI) implementation

Y Implemented Roton

Y Implemented Roton 3 months

12,259 Y Planning Stage Roton 1 months

8,764 Y Implemented

7,148 Y Implemented Manik

 Y Manik

Y Furuk Ahmed

2,190 Y

9,386 Y

42,209 N

16,034 N
Projected annual Accept (Y/N) Status of the Directly Responsible Timeframe for
benefits, USD Recommendations Person (DRI) implementation

Y Implemented Manik

12,566 Y Implemented Manik

49,073 Y Implemented

3,129 N Not Accepted

Y Implementation Stage Akeam & Manik Continous

41,995 Y Not Implemented Manik

9,211 Y Implemented Manik

2,599 Y Implemented Manik

 6,684 Y Planning Stage Manik

9,211 N Not Accepted

68,436 Y Implemented

1,820 Y Pre-Planning Stage Manik Continous

al Savings for Utility (Yearly) Total Resource Savings (yearly)
- m3 Water Savings - m3
- m3 NG Savings - m3
- kWh Electricity Savings - kWh
- Ton Steam Savings - Ton
- Ton GHG - Ton

Allocated Monitoring
budget team
BCAS
Allocated Monitoring 28-Mar 25-May 23-Jun
budget team

BCAS
Implementation Actual Investment
Actual Savings
(USD)
 - -

Actual Investment Actual Savings

(USD) (USD)
28-Jul 30-Aug 23-Sep Implementation Actual Investment Actual Savings
(USD) (USD)
- -
- -
- -
 Water Savings NG Savings

m3 BDT USD m3 BDT USD

- - - - - -

Water Savings NG Savings

m3 BDT USD m3 BDT USD
- - - - - -
0 0
 Electricity Savings Steam Savings

KWh BDT USD Ton BDT USD

- - - - - -

#REF!

Electricity Savings Steam Savings

KWh BDT USD Ton BDT USD
- - - - - -
GHG

Ton
 -

GHG
Ton
-

0
ACTION PLAN ON CLEANER PRODUCTION ASSESSMENT (CPA) FINDINGS & RECOMMENDATION
AREA OHS, EMS, WASH & CHEMICAL INVENTORY

CP ASSESSMENT OUTCOMES AND ACTION

# Assessment area Findings

1 During the assessment period, it

was observed that the floor was
very wet and slippery and
liquids are not cleaned up
immediately in the washing
section.

2 \During the assessment period, it

was observed that the aisles and
passageways in the washing
section and dyeing section are
blocked by fabric materials and
cartons.

3 \During the assessment period, it

was observed that it is observed
that the operators do not use the
noise cancelling headphones and
OHS/EMS/WASH ear-plugs properly as per
requirement especially in the
boiler and generator area.
4 \During the assessment period, it
was observed that the solid
wastes and wastage materials
were not segregated properly.
The solid waste materials and
other wastages been kept at the
same place in an open area
without being segregated. The
waste disposal area was
5 During
observed thewater
assessment
logged period,
as well.it
was observed that the chemical
sub-store is untidy. Salts are
found spread over the floor. Spill
kits are not available in the sub-
storage. It was also observed
that there are no separate room
for the in-charge of the chemical
store. Ventilation in the chemical
store was also observed poor.
6
ESSMENT (CPA) FINDINGS & RECOMMENDATIONS
MS, WASH & CHEMICAL INVENTORY

CP ASSESSMENT OUTCOMES AND ACTION PLAN

Recommendations Accept Directly

(Y/N) Responsible
Person (DRI)

\Improve housekeeping (clean up the water

and other spilled materials) is inevitable in
the washing floor

Y Ohidul Islam

\Improve housekeeping by proper

organization of fabric materials and cartons
from the aisles and passageways.
Y Ohidul Islam

\Use noise cancelling headphones and ear-

plugs properly in the boiler and generator
area
Y Ohidul Islam
\Proper segregation of solid wastes and
wastage materials need to be done

Y Ohidul Islam

\Standardize the chemical sub-store and

Y Ohidul Islam
dyes store

Training Session for Resource Savings

Y Ohidul Islam
(Water, NG, Steam & Electricity
Timeframe Allocated Date Monitoring Updates Date
for budget team
implementati
on

1 month
1 month

1 month

1 month
 MONITORING DETAILS

MONITORING (MONTHLY BASIS)

Monitoring Updates Date Monitoring Updates Date Monitoring

team team team
LS

BASIS)

Updates Date Monitoring Updates Date Monitoring Updates

team team
Actual spend
money, USD