Energy Assessment case study of a garment manufacturing factory in Bangladesh

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Executive Summary

ILINK Development Services conducted an energy assessment at a Printing & Embroidery unit in Bangladesh to evaluate energy consumption and identify efficiency opportunities. The assessment revealed that the supplier relies on electricity from the national grid and natural gas for its captive power plant, with an average energy consumption of 0.478 kWh per garment. Key findings include high baseline energy use, even at zero production, and a 30.05% variation in energy efficiency across months. Recommendations include installing a hot water chiller for jacket water heat recovery, replacing conventional ceiling fans with BLDC fans, and upgrading metal blade exhaust fans to FRP blade types, yielding significant ROI (0.86–2.16 years). These measures could reduce energy costs, lower the carbon footprint (3.49 kgCO2/kg production), and enhance sustainability.

Major Learnings for Industries

Baseline Energy Waste: High energy consumption during non-production periods indicates inefficiencies in standby systems.
Variable Efficiency: Significant monthly variations in energy per unit suggest inconsistent process optimization.
Heat Recovery Potential: Unutilized waste heat from generators presents a major energy-saving opportunity.

Recommendations

Install hot water chiller for jacket water heat recovery (BDT 17.5M annual savings, 0.86-year ROI).
Replace conventional fans with BLDC fans (BDT 444K savings, 2.16-year ROI).
Upgrade exhaust fans to FRP blade types (BDT 2.7M savings, 1.20-year ROI).
Enhance PPE compliance through training and inspections.

Conclusion

The supplier’s energy intensity is satisfactory, but implementing recommended measures can significantly improve efficiency, reduce costs, and align with sustainability goals, reinforcing its commitment to environmental responsibility.

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