Executive Summary
Levi Strauss & Co. (LS&Co.), a global leader in denim, partnered with ILINK to conduct an energy audit at a key supplier in Bangalore, India, specializing in denim garment washing. This initiative aligns with LS & Co’s corporate climate targets to enhance resource efficiency and reduce Scope 3 emissions across its supply chain. The supplier equipped with a modern zero-liquid discharge (ZLD) effluent treatment plant, relies on minimal fresh water (2-3% of total consumption), showcasing its commitment to sustainability. The assessment focused on the cut-pack and washing plants, identifying actionable energy-saving measures. Key recommendations include utilizing boiler flue gas heat for drying via heat exchangers, installing variable frequency drives (VFDs) on blower pump motors, and conducting compressed air leak surveys to maintain leaks at 10% of industrial standards. These interventions will collectively save 17,190 kWh annually, reduce costs by $2,050, and cut Scope 2 emissions by 14.01 TCOe, with VFDs offering a payback period of less than one year. The audit highlights the supplier’s potential to lead in sustainable denim production and provides a scalable model for LS&Co.’s supplier network. By implementing these measures, the supplier can further align with global sustainability benchmarks, reinforcing LS&Co.’s commitment to a low-carbon supply chain and setting a precedent for the garment industry to adopt energy-efficient practices through strategic partnerships.
Major Learnings for the Industry
Recommendations
S no | Recommendation | Benefits |
1 | Implement Flue Gas Heat Recovery | Use heat exchangers to convert boiler flue gas heat into heated air for drying washed denim garments, enhancing energy efficiency. |
2 | Install VFDs on Boiler Motors | Equip blower pump motors with variable frequency drives to achieve 15,000 kWh in annual energy savings, $1,750 in cost savings, and a 12 TCO₂e reduction in Scope 2 emissions. |
3 | Conduct Compressed Air Leak Surveys | Perform detailed surveys to reduce leaks to 10% of industrial standards, saving 2,190 kWh, $300 in electricity costs, and 2.01 TCO₂e in Scope 2 emissions. |
4 | Expand Energy Audits | Regularly audit both cut-pack and washing plants to identify additional energy-saving opportunities and align with LS&Co.’s Scope 3 emissions reduction targets. |
5 | Scale Best Practices | Share successful interventions (e.g., VFDs, leak repairs) across LS&Co.’s supplier network to amplify sustainability impacts. |
Conclusion
The energy audit at a key LS&Co denim supplier underscores the potential for targeted interventions to enhance energy efficiency and reduce Scope 2 emissions in garment manufacturing. Implementing flue gas heat recovery, VFDs on boiler motors, and compressed air leak repairs will collectively save 17,190 kWh, $2,050 annually, and 14.01 TCO₂e in emissions, with payback periods under one year for VFDs. These measures align with LS&Co.’s corporate climate commitments and demonstrate a supplier’s proactive approach to sustainability, supported by its modern zero-liquid discharge (ZLD) effluent treatment plant. The partnership between ILINK and LS&Co. exemplifies how collaborative audits can drive resource efficiency, positioning the supplier as a leader in sustainable denim production and offering a replicable model for the industry.
