Environmental and Energy Management in a Textile Dyeing ... - IGES

Self-regulation
The need for improvement in auditing and benchmarking
The principal motivation for the company to develop cleaner production methods is the
reduction of costs associated with inefficiencies within their operation. Upper
management was able to reduce these costs through energy auditing and benchmarking.
These are effective tools for an organisation to monitor the actual performance of their
company, to recognize inefficiencies, discover where there is room for improvement, and
finally be able to improve performance.
Technologies
Installation of automatic equipment to improve efficiency
Retrofit of the boiler system played an important role in improving the energy efficiency
of the factory, eliminating steam release, and improving efficiency of their equipment.
The improved technology provided a great opportunity for the factory to reduce heat loss
due to the release of steam and the accumulation of condensate in the piping system.
Moreover, in the colour-matching processes, a computerised colour-matching device was
installed to enhance speed and accuracy, resulting in fewer defects and increased
customer satisfaction. Introduction of these new technologies assisted the company in
improving its performance.
Impacts
• The company developed an environmental and energy management system as a
management tool and a fundamental framework for the company to move toward better
production efficiency. They can thus recognise problems and inefficiencies, and
subsequently, they set up a continuing improvement program.
• Implementation of cleaner technology resulted in cost reductions. For example, the boiler
and steam trap retrofit led to a 20 percent reduction in fuel oil consumption.
• Cleaner technology practices also help in increasing customer satisfaction due to better
quality of product and services. For example, the colour-matching process can now be
completed within two to three days, whereas it used to require ten to fifteen days.
• Personnel involved in establishing environmental and energy management systems have
consistently developed the knowledge and skills necessary for implementation of resource
energy efficiency. In addition, operational staff have also developed better working
procedures in order to eliminate waste and reduce losses in the production process.
• Sinsaenee Company can be used as a demonstration model for steam trap retrofit
adaptations so that interested parties in other factories could benefit by adopting this
technology.
Lessons Learned
• A strong commitment from upper management is vitally important for improving
efficiency in manufacturing enterprises. In this case, the managing director played a key
role in promoting organisational changes, which then stimulated employees to actively
participate in implementation.
• An environmental and energy management system is an effective instrument for
continuing improvements, because it provides the basic tools for systematic monitoring of
performance.
• Performance improvement is a continuous learning process in which returns from previous
adaptations could be incentives that reinforce further developments and better efficiency.
• Improving environmental and energy performance can be seen as a means of increasing
resource efficiency, leading to cost reductions and higher profits. Accordingly, the
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