Professional Documents
Culture Documents
Implementation Bodies
SIGMA Consultants (GR)
Hellenic Fashion Industry Association (GR)
CITEVE - Centro Tecnológico Das Indústrias Textil e do Vestuário (PT)
AITEX - Instituto Tecnológico Textil (ES)
Black Sea Regional Energy Centre (BG)
Bulgarian Association of Apparel &Textile Producers & Exporters (BG)
July 2007
TABLE OF CONTENTS
1 INTRODUCTION.................................................................................................................... 3
1.1 Summary of the Project..........................................................................................................3
1.2 Work plan and methodology ..................................................................................................4
2 IMPLEMENTATION BODIES ................................................................................................ 7
1 INTRODUCTION
1.1 Summary of the Project
The energy management system that was developed was based on the accumulated
know how and experience from environmental and energy management applications and
was tailored for the specific needs and characteristics of typical Small Medium size
Enterprises (SMEs), which represent the majority of the textile enterprises of the
participating countries. The energy management system is simple to implement and
sustain and it is focused on the application of energy efficiency interventions and
monitoring and not on written procedures that require external certification/verification (like
Environmental Management Systems according the ISO 14001:2004 Standard or the
EMAS EC 761/2001 Regulation).
Within the current project specific energy management practices were gathered in a
Guide focused on the textile sector, including a number of practises and interventions
applicable to more industrial sectors as well. The proposed practises were implemented in
the energy field of various textile companies, aiming though to be adopted from
companies of other sectors as well, via the motivation of the enhancement of efficiency
and competitiveness. This project was mainly focused on the textile industries of the
participating countries but experience and knowledge exchange was conducted with
executives from various sectors and representatives from relevant IEE projects.
State of the art energy management and conservation practices implemented successfully
through out the world were reviewed and assessed according to their results and
applicability for the conditions of the typical textile enterprises of the participating
countries. The requirements of the energy management system standard, the guidelines
for its implementation and the energy conservation practices for the achievement of high
energy efficiency were compiled as well as the promotion and support of the proposed
practices implementation.
An appropriate energy audit methodology for the textile sector was developed and a
supportive Energy Audit Tool was prepared. Special energy consumption data from
various countries from all around the world were collected for the creation of a
Benchmarking Report and the respective Benchmarking Tool both of which can be used
for the energy performance evaluation of the textile companies. Pilot energy audits were
conducted, three in each participating country, according to the EMS-Textile audit
methodology. Energy conservation and efficiency measures were recommended for the
energy intensive textile operations, exploiting all the accumulated know how on EU and
global level. The proposed practices are divided to those about the conservation of heat
and to those about power. Further more Pilot Implementations of the proposed energy
management practices - one at each participating country - were realised, in order to
review the proposed methods and demonstrate their benefits to stakeholders.
For the promotion of the project’s outcomes four Textile Energy Offices (TEO) - Help
Desks were established, and thus the Energy Efficiency Network (EEN) was formed,
consisting of 200 stakeholders, 50 from each participating. The EEN will serve as the
necessary critical mass for the project information dissemination, whereas the operation of
the TEOs, even after the completion of the project, will ensure its continuation and effect.
In general every action and output of the EMS-Textile project was designed and
elaborated or produced considering the respective state of the art and success stories on
global level.
The project was divided into eight Work Packages which included three or four specific
actions. The division of the project into Work Packages was based on their specific
objectives. Most of the Work Packages were scheduled in a sequential order, because
their outputs were utilised in the next Work Package. Exceptions to this rule were the
Project Management Work Package which was continuous and the Dissemination Actions
which were carefully scheduled in key periods during the project’s elaboration.
More specifically the first Work Package encompassed the Project Management Actions:
the project organisation, the formation of the project teams, the task allocation, the
implementation plan, the monitoring and evaluation system and the submission of all the
project reports.
The objective of the second Work Package was the determination of good energy
management practices based on state of the art know-how and experience. The first step
was the conduction of a review in order to establish a base line for the textile sector and
for the applied and tested energy management practices. The study of the energy
management systems, via the review process, outlined the methodology and purpose of
the Energy Management Standard proposed by the EMS – Textile project. After the
completion of the recommended standard, the development of the Energy Management
Guidelines began in order to facilitate its implementation. The recommended practices
were selected from other relative guides and tailored to the needs and characteristics of
typical industrial SME’s of the participating countries.
Supplementary the third Work Package of the Energy Management Tools provided useful
instruments for the implementation of the Energy Management System, like the Energy
Audit Methodology, the Benchmarking Database and the Energy Efficiency Practices
Issue.
The objective of the fourth Work Package was the support of the promotion of the Energy
Management Practises and Tools in each participating country that would multiply the
dissemination effect and involve the key actors of the project. Textile Energy Offices were
formed in order to provide technical support and perform the dissemination actions in
every participating state and in the European Union. The Energy Efficiency Network that
was developed actively involved the associated parties with the project actions. The
creation of the web page made all the important information of the project available to the
entire world. Informative Leaflets in all languages plus English were produced and
distributed whereas Informative Workshops about the energy management practices and
tools were conducted in the all participating countries.
In the fifth Work Package, the Energy Management Training provided extensive
knowledge to selected key actors that could begin the utilisation of the proposed practices
and tools. During the sixth Work Package of the Pilot Implementations, the proposed
practices and tools were tested and evaluated in real industrial conditions; respective case
studies derived.
In the seventh Work Package about the project exploitation: all the project outcomes and
conclusions were utilised via the creation and dissemination of the Good Practice Guide
CD. A Project Evaluation Report was prepared in order to review and evaluate the
project’s implementation success. Its main objective was the investigation of the degree of
effectiveness of the activities elaborated within EMS - Textile, compared to the targets set,
as described analytically in the approved by the EU co financing proposal. The
sustainability of the Textile Energy Offices is assured via the design and execution of the
respective Action Plan. The compilation of the Action Plan took into account current
market demands for energy related services, according to the experience gained by the
implementation of the EMS-Textile project so far and from past activities of the project’s
partners.
The full exploitation of the project was achieved via the dissemination of all the important
project information in the participating countries and the EU. The wide promotion of the
objectives and outcomes of the current project was ensured via the realization of the
eighth Work Package.
2 IMPLEMENTATION BODIES
The Black Sea Regional Energy Centre was established following the
Chalkidiki Ministerial Meeting in May 1994 at the joint initiative of the
European Commission under its SYNERGY programme and eleven
countries of the Black Sea region. Currently, BSREC has 13 member-
countries, i.e. Albania, Armenia, Azerbaijan, Bulgaria, Georgia, Greece,
Moldova, Romania, Russian Federation, Turkey, Ukraine, the former
Yugoslav Republic of Macedonia and Serbia & Montenegro. The BSREC
was officially registered in 1995 in Sofia, Bulgaria and it acts according to the Bulgarian
legislation. The BSREC activities are aiming at the harmonization of the energy policy of
the BS region countries with the EU, the facilitation of implementation of long/medium
term integrated strategy of security of supply and sustainable development, the provision
of co-ordination services for international and bilaterally funded projects, addressing the
individual countries and easing the access of foreign and international institutions and
companies to the Black Sea region countries' energy sectors. Apart from its international
activities, the BSREC devotes significant efforts to Bulgarian energy issues and in this role
the Centre is acting as a Bulgarian energy society.
2 P.Ioakeim Str. 546 22 Mr. Manoloudis 0030 2310 0030 2310 A.Manoloudis@
SIGMA Consultants
Thessaloniki, Greece Thanasis 242801 286612 sigmaconsultants.gr
Bulgarian Association
of Apparel and Textile 2 Omurtag Str. Ms Dankova 00359 2
00359 2 9693161 v_dankova@bgtextiles.org
Producers and 1124 Sofia, Bulgaria Valia 9693181
Exporters
clothing and textile imports increased 27% while the respective increase of exports was
12%. The worrying fact is that imports are increased from both developed and developing
countries. The import increase from EU states reached 24% while from China 34%. These
figures are quite worrying and combined with the transfer of Greek companies to
neighbouring countries like Bulgaria and FYROM further worsen the picture.
However the importance of the sector for the national economy remains great, since it
employs thousands of employees and represents more than 20% of the national exports.
The late global developments have threatened the position of the entire European textile
industry and combined actions are planned to face this situation. For this reason EURATEX
the European Association of Textile Federations has financed the conduction of a special
market research and has established a High Level Group, which will try to find ways and
measures to face this problem.
and on flexibility. Today the textile sector of Portugal represents almost 3% of the national
product, more than 6% of national employment and more than 20% of national exports. For
the last 2 decades, there has been an annual average productivity growth rate of 2.5% in
the clothing sector and 1.8% in the textile sector.
However the development of the industry is subject to strong constraints, such as: The
progressive integration of the textile and clothing business, the market liberalisation, the
entrance of China into the World Trade Organization and the anti trade business practices
used by China and other Asian countries. Markets such as the one in the European Union
are totally open to products coming from any origin. However, the exporting countries do
not comply with the rules, which were established in the Textile and Clothing. The world
trade has certain rules that must be followed by all competitors.
Status of the Textile Sector in Spain
The textile sector holds a significant position within the Spanish industrial structure, as it
employs directly 275,000 people, 10% of industrial employment and contributes 5% to the
Gross National Product. The majority of the companies are small and medium sized
enterprises (SME), as this type of company has a greater flexibility to adapt to evolutions,
which are very often especially due to the phenomenon of fashion.
Evolution by products is very diverse: Exports of fabrics (natural and chemical) are reduced,
basically due to lower world demand and to the decline of average prices. The decline of
European demand causes a limited growth of yarns and fabrics. The highest increases of
exports are in finished garments (knitting and clothing) with 15%. This figure reflects the
foreign expansion of companies with their own distribution networks.
Overall imports grow; several textile products follow an evolution very similar to that of
exports: Material purchases diminish as a consequence of the lower spinning activity, the
abundant offer of Spanish cotton, and the general fall of fibre prices. Yarns and fabrics
reduce their imports due to the decline of internal production and the lower external
pressure caused by the market recovery of bidding countries. Opposed to these facts,
imports of clothing increase. This figure reflects the good working of internal market. The
balance of trade declined, whereas the hedge rate (% Exp./Imp.) reached 73%. According
to products, the trade balance improved in materials and textile manufactures; whereas the
deficit of final product manufactures underwent a significant increase (+24%) and
represented 83% of the overall deficit, opposed 76% of the previous year.
Joining the European Union in 1986 represented the full incorporation of Spanish
companies in the world market of textile and clothing goods. Companies have taken
advantage of this fact and they have constantly increased their presence in foreign markets.
Likewise, in 1999 total exports went over 30% of production. The Spanish textile and
clothing sector offers a wide range of products fulfilling the conditions required by the
international market regarding quality, design, price, and service. Two-thirds of Spanish
exports are aimed at the European Union, although sales in North America, Middle East,
and Latin America are notable. However the last developments in the world textile market
and especially the strengthening of China’s position could not leave the Spanish textile
industry unaffected.
Status of the Textile Sector in Bulgaria
The textile industry is the main and oldest light industry branch in Bulgaria. The beginning
of factory textile manufacturing was laid in the second quarter of the 19th century. During
the 1940-1950s the textile industry became one of the leading sectors in Bulgaria, second
in importance after the food and beverage industry. It keeps this position up till present
days. In 2007 the textile sector encompasses over 176,000 people staff.
It includes the following activities:
- buying up and primary processing of natural textile raw materials;
- cotton-textile
- silk-textile
- wool-textile
- hemp and linen
- knitwear
- unwoven textile
- sewing
The sector includes production of yarns, cloths and products made of these, intended for
clothing, domestic and technical purposes. The sector’s activities are characterized with
significant and quick dividends, both for the sector and for the national economy as a
whole.
From the study derived the following strengths of the Bulgarian textile sector:
Infrastructure – the production infrastructure built during the planned economy period
is relatively well developed and is typical for industries which have manufacturing
experience and traditions. This infrastructure allows Bulgaria to be a competitive
supplier to international markets.
Quality – The majority of the Bulgarian producers have the capability to manufacture
goods of quality complying with global standards.
The capability of the companies in the sector to produce goods corresponding to the
fashion trends, and meeting consumers’ requirements in terms of price, functionality,
and design provides for the demand for our merchandise at the international and
domestic markets. The merchandise is aimed mostly at the middle-class consumers.
Technologies are being developed for environmentally clean production. Some of
the companies hold the ISO 9000 quality certificate.
Availability of Prime and Raw materials – Bulgaria is also a producer of natural and
chemical raw materials having the required quality. The country’s capacity can meet
a possible future increase in the demand.
Labour Costs – the high qualification and the low labour costs make Bulgaria
competitive at the international markets.
Production Capacity – a large part of the companies have a closed cycle production.
In the textile, knitwear, and the sewing industries technological connections have
been established, which determine covering of the separate production stages.
In the textile industry the technological processes, involving processing in the
different factories, cover one or several stages of the textile manufacturing – primary
processing of natural or synthetic fibres/silks, spinning, weaving, and refinement of
the semi-finished and finished goods.
dyeing and finishing facilities the rest textile operations do no consider energy conservation
as a top priority.
On cost – benefit basis the energy conservation potential of most Greek industries is
estimated between 10 and 15%. In some cases it can be as high as 25%. The required
technical know how is available in Greece. In all the completed energy projects, more than
70% of the total contribution in labour, materials and equipment was of Greek origin.
control load and peaks, use of natural cold air from, good maintenance to reduce the
leaks.
Thermal Energy is used at heat processes mainly in dyeing, drying and finishing
operations. The thermal energy saving measures can be divided again according to their
area of implementation:
General: Thermal insulation and good maintenance of equipments and pipes, thermal
insulation of condensate and oil tanks, installation of cogeneration systems that
produce steam and electricity.
Boilers: Substitution of fuel oil or diesel with natural gas boilers, recovery of the
condensates, combustion control system to regulate the fuel air mixture, good
maintenance and periodic combustion control, recovery heat from exhaust air to pre-
heat the water or the inlet air.
Drying: Installation of direct natural gas burners in dryers and stenters, mechanical
extraction of water from fabric before drying, heat recovery from exhaust air to pre-
heat water or the inlet air equipment, installation of humidity control in the exhaust air
of stenters and dryers.
Dyeing: Use of equipments with low-liquor ratio and heat recovery from hot effluents
to pre-heat the inlet water.
Some energy intensive industries monitor their energy consumptions with electricity
counters for the entire factory or for the more important consumers, and with automatic heat
measuring equipment. This data is later analysed by the operator manager who takes
immediate remedial action or proposes conservation measures to top management.
Considering the two biggest certification bodies of Portugal, the textile companies certified
with ISO 9001:2000 and ISO 14001:2004 are 222 and 24 respectively. Energy and
environmental performance of enterprises is proportional to their competitiveness. As the
power of the companies grow so does the implementation of good environmental and
energy practices. These companies benefit from cost reductions, profile improvement and
from the good relations with the public authorities and the local communities.
In Portugal energy intensive consumers have to accomplish the Regulation for Energy
Consumption Management (RGCE), realize energy audits and implement efficiency
measures. This regulation is for all industries intensive consumers, which:
During the last year energy consumption was higher than 1000 toe (tonne oil
equivalent)/year
All equipments’ nominal consumption of energy are higher than 0,5 toe/hr
Results Oriented Report Page 18 of 57
Europe Intelligent Energy Program EMS – Textile Project
At least one equipment’s nominal consumption of energy is higher than 0,3 toe/hr.
All industrial energy intensive consumers have to do an energy audit every five years.
During this period they must monitor and track energy costs and consumptions, and
implement good practices for the reduction of energy consumption.
The recommendation of the EMS-Textile project has the same structure with EMAS and
ISO 14001, but it is much easier to adopt and requires minimum documentation. It can be
implemented alone or in combination with the above environmental management systems.
performed in three to five days by one or two competent energy auditors, depending on the
size site and the data availability. The tool provides a general indicative approach and can
be modified easily according to the site’s special requirements. It was developed in excel
format in order to facilitate modifications and facilitate calculations. The Audit Tool is divided
into the following Data Sheets:
General Data Productive Equipment
Financial Data Auxiliary Equipment
Consumption Data Building Data
Check Points Management Matrix
Production Flow Audit Conclusions
Energy Flow
The following Table 2 shows the Matrix (included in the Tool) assessing the performance of
the Energy Management System adopted at each company.
The applicability of the Energy Audit Tool had to be tested and consulted with its potential
end users. Therefore twelve Pilot Energy Audits were conducted, three in each participating
state for the testing of the tool and for the gathering of first hand energy consumption data.It
must be pointed out that the EMS-Textile Audit Tool was used extensively in relevant
activities of the BESS sister project.
Thus the necessity for the creation of the Benchmarking Information report arose. The
data for this report were derived from research in existing information sources, from past
experience of the project partners and from the elaboration of the Pilot Energy Audits. Many
factors affect special energy consumption of a company, the most important of them are the
specific characteristics of each different product. Therefore the information of the
Benchmarking Report should not be used for direct evaluation assessments, but as an
indicative reference of magnitude order.
The data presented in the following Table were gathered via the pilot energy audits
conducted in each participating country. The data do not represent the entire textile sector
of each country, but only the companies examined. The numbers in the parenthesis present
the level in of the first, second and third company examined in each country respectively.
Further more, in Bulgaria, BSREC realized visits and mini audits to the following textile
enterprises were the heating and illumination conditions were investigated:
“SVILOZA” – Svishtov “MAROLIO” – Sliven
COATS – Sofia “STIL” – Vratza
“MAK” – Gabrovo “SILK” – Svilengrad
“SEVT” – Kazanlak Wool Processing Factory –
“FILTEX” – Kazanlak Parvomay
“BULGARIA” – Kazanlak INKOTEX - Kotel
The general conclusions confirmed the overall assessment that the energy use conditions
have big margins of improvement. In order to start the implementation of Energy
Management Systems first of all the enterprises must install metering systems allowing
breaking down the energy consumption according to processing phases / technologies,
which is an obligatory condition for energy analyses.
Interesting detail is that usually Company Management Officials are more interested in EM
than the energy departments, who in some cases resist against the proposed systematic
approach.
1. Dyeing and finishing of fabric: Wet batch processing under pressure with jet
machines, modern technology and equipment, energy conservation measures
implemented.
2. Spinning: Indicative data from state of the art production technology where energy
conservation measures and monitoring techniques are implemented.
3. Denim Fabric production: Dyeing 50% of cotton yarn => Weaving 50% dyed cotton
yarn with 50% not dyed cotton yarn => denim fabric finishing. Modern technology with
no energy conservation measures implemented. (Approximately 200 gr/m2 denim fabric
=> 3,500 ton = 700,000 m2).
10,0%
9,0%
8,0%
7,0%
6,0%
5,0%
4,0%
3,0%
2,0%
1,0%
0,0%
1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003
The Portuguese energy system depends too much from one single source: oil. Since some
years, natural gas has occupied a very important place, in many cases substituting oil,
making the equipment more efficient in terms of energy consumption and environmental
friendliness. Concerning electrical energy the companies can choose their supplier, so the
prices become more competitive which makes the final product also more competitive. In
general, energy in the textile industry is mostly used in the forms of: electricity, as a
common power source for machinery, cooling and temperature control systems, lighting,
office equipment, etc.; LPG, Fuel-oil and natural gas for steam generators, for thermal-oil
boilers and for burners or dryers to heat directly the air. There are some industries, which
buy steam and electricity to an associated cogeneration facility. Others industries with
cogeneration systems, consume the steam and sale the electricity.
160 000
140 000
120 000
Energy Consumptions (toe)
100 000
80 000
60 000
40 000
20 000
0
LPG Gasoline Diesel Fuel Lubrificant Natural Gas Electricity Heat Vegetal
Firewoods
and Residues
1. Dyeing and finishing of home textiles: Wet batch processing under pressure with
jet machines, modern technology and equipment, energy conservation measures
implemented.
2. Dyeing, printing and finishing of upholstery fashion and home textiles: Various
dyeing and finishing processes according to the various technical requirements and
specifications of different products.
3. Spinning, printing and finishing of blankets and bed covers: Extensive leak
deduction programs are implemented for air, steam and water. Considerable savings
in electricity consumption can be achieved via the installation of VSD motors and the
use of 3-phace AC current.
1. Fabric Production: Vertical process, spinning, weaving and fabric finishing. The main
production process includes degreasing, drying, steaming, spinning, weaving and
finishing. Factory operation around 65% of total capacity.
Table 14 – Comparison of energy intensity in textile industry in Bulgaria and the World
In comparison with the world practice, the specific energy consumption in Bulgaria is
1.3÷1.8 times higher for cloth finishing and dying, and 1.35 times higher for yarn dying.
Finishing in textile companies is the major energy consuming process – 75% of the steam
and 25% of the electricity in textile industry are used for the textile-chemical or finishing
processes. The energy costs for this part of textile manufacturing processes are 14% of the
total costs of a company, while a total of 30% is spent on raw materials, dyes, and
chemicals. The reasons for this disappointing situation are various: inefficient building
constructions, obsolete technology, incompletely or irrationally used production capacity,
etc. These facts unambiguously indicate the importance of energy management in order to
mitigate the negative effect of the high specific energy consumption on the competitiveness
of Bulgarian textile production, as well as the reduced possibilities for its realization.
Based on the relative energy data from all patrners, a simplified Benchmarking Tool was
developed in order to allow textile companies to asses their energy performance in general
terms. The Tool was included in the Good Practise Guide CD. Its interface is shown below.
Figure 4 – Benchmarking Tool
Finally the Energy Efficiency Practices Issue was compiled, including energy
conservation measures for the textile processes. The project coordinator initially assigned
different groups of energy conservation measures to be separately developed by SIGMA,
CITEVE, AITEX and BSREC. The results were gathered by SIGMA; the respective draft
issue was compiled and sent for consultation to all partners before receiving its final form.
The practises presented at this issue were divided in to two main categories the ones
aiming to the conservation of heat and to the others aiming to the conservation of power.
The techniques for heating energy conservation are divided into the following chapters:
Heat recovery in dyeing and finishing processes, Types of Heat Exchangers, Heat
Distribution, Boilers and Burners, Cogeneration, Renewable Energy Sources, Various
Fuels. The power saving measures, included in the Guidebook, refer to the following
categories: Motors and Pumps, Variable Speed Drives, Pump Selection, Compressed Air,
HVAC Systems, Lighting, Electric Installation. The energy efficiency guide in combination
with the energy audit tool the energy management guidelines and the supportive
information of the www.ems-textile.net provide a sound basis for the improvement of energy
performance at industries and not only for the textile sector.
Their mission is the dissemination of the energy efficiency good practices, the energy
management principles and the monitoring and targeting actions to the associated bodies
and enterprises. They undertake the task of disseminating all the project deliverables and
provide technical support to textile industries interested in implementing the proposed
practices. Furthermore they will help companies financing energy investments by informing
them about current national or European funding opportunities.
Their activities are co-ordinated by the Steering Committee and directed by the leader of
their National Project Team. Initially they were staffed by both technical and administrative
personnel in order to be able to offer high level integrated services. The TEOs provide
technical support and consultations to textile industries, including:
Energy audits and diagnostics
Energy consumption rationalization plan
These offices operate as sustainable business units after the end of the project i.e. from
July 2007. To do so, their services and requirements in personnel, infrastructure and
equipment should be carefully planed according to related revenues and expenses. Thus a
detailed Action Plan was prepared, providing guidance for the management of the TEOs in
a sustainable way. The compilation of the guide took into account current market demand
for energy related services according to the experience gained by the implementation of the
EMS-Textile project so far and from past activities of the project partners. Many of the
services and considerations described in the Action Plan have already been implemented
successfully.
In the beginning of 2006 the Energy Efficiency Network (EEN) was formed, consisting of
200 textile industry executives and other stakeholders (energy consultants, technical
scientists, and engineers, representatives of authorities and educational institutions), 50
from each participating country. In Spain and Portugal AITEX and CITEVE formed the
network, in Greece and Bulgaria it was formed in cooperation of the two bodies, but the role
of the two associations SEPEE and AATEB was prominent. The members of the EEN are
co-ordinated by the relevant Textile Energy Offices. Their suggestions were taken into
consideration during the project’s execution. Furthermore a large part of the Project
Evaluation was based on their views.
The TEO’s website www.ems-textile.net is in operation since February 2006. It contains
all the important project information, news, deliverables, contact details, links, etc. It is
updated regularly in order to present all the project’s deliverables. It was created under the
supervision of SIGMA and all partners provided input especially in their national languages,
since the site is multilingual providing information in English, Greek, Portuguese, Spanish
and Bulgarian.
Informative Leaflets in all languages plus English were produced and distributed.
Informative Workshops were conducted in all participating countries. The Energy
Management Practices and the activities of the EMS-Textile project were the main issues
discussed at the workshops. Two presentations one about Energy Management and one
about the EMS-Textile project were used in all workshops. In Greece technical input was
provided by SIGMA, while the organisation of the workshop was made by SEPEE. In
Bulgaria Energy Management Practices were presented in five cities covering the entire
country, in Vratza, Russe, Varna, Burgas, Stara Zagora during January 2006, in Sofia in
February 2006 and in Pleven in April 2006. All presentations were made by BSREC with
the support of the Bulgarian Ministry of Development and of AATEB. In Portugal the
workshop was planned and elaborated by CITEVE. In Spain it was conducted solely by
AITEX.
The training seminars in Greece took place between the 11th and 12th of December 2006,
and were organized by SEPEE, with technical input and trainers provided by SIGMA
Consultants. The seminars took place at Thessaloniki at the premises of the Institution of
Education and Lifelong Learning ‘’Endysi’’, according to the following program:
Section 1: 11th of December 2006 from 17:00 to 21:00 hours; Subject: EMS-Textile
Project presentation. Energy Management: Introduction to Energy Management,
Elements of Energy Management, Energy Policy and Energy Targets, Energy
Management Measures, Monitoring and Targeting, Energy Management Review.
Trainer: Ioannis Ioannidis
Section 2: 12th of December 2006 from 17:00 to 21:00 hours; Subject: Energy
Conservation at the Textile Sector: Heat Recovery in Dyeing and Finishing, Energy
Savings in Heat Distribution Network, Efficient Operation of Boilers and Burners,
Energy Conservation in Motors and Pumps, Power Factor and Harmonic Distortion,
Funding Opportunities for Energy Investments. Trainer: Thanasis Manoloudis
Number of trainees that participated in the seminars: 20.
The energy management training in Spain took place in four days, on 11, 13, 18 and 20 of
December 2006. During the first day the concepts of energy management, energy policy,
energy audit and action planning were discussed. The second day was dedicated to
internal structure and responsibilities assignment. The third day focused on the energy
monitoring techniques and the last day on the review of the energy management system.
The number of trainees was twenty one; some of them were from AITEX, while most of
them were from textile companies. The entire training was based on the Energy
Management Manual. The trainers of the seminars were José Gisbert, Ascensio Asensio
and Ignacio Corbí, engineers and technicians specialised in textile processes.
Bulgaria: The following training materials were elaborated within the frame of the project –
Energy Management Guidelines, Energy Management manual, set of lectures of Prof.
Kaloyanov “The Fundamentals of Energy Management”, and Prof. Vassilev “European
Norms and Energy Efficiency of the Lighting in Industry”, Energy Management Tool. The
aforementioned material was disseminated via the Bulgarian TEO. BSREC and AATEB
organised two training courses in Bulgaria. The first was held in July 2006 consisting of 61
teaching hours’ lectures and 14 teaching hour’s exercises and the trainees had to pass a
concluding test. The scope of the course included: specific regulatory framework
requirements, the basic principles of energy exchange in industrial sites, energy efficiency
audit techniques, methods for identification and assessment of the energy performance,
specific measures for reduction of energy consumption and energy monitoring techniques.
The second one was short intensive and took place on 15 December 2006 at INTERPRED
premises. The main instructors in both seminars were Assoc. Prof. Dr. Lulin Radulov,
director of BSREC and Assoc. Prof. Dr. Nikola Kaloyanov from the Technical University of
Sofia. The trainees were from Energy Service Companies, municipal energy departments,
enterprises energy department and postgraduate students.
The trainees usually have a good background in energy problems and the training courses
provide them with a systematic approach to energy management. It will be very useful
however if the fundamentals of Energy Management are included in the University
Programmes. BSREC has undertaken the first steps to this direction in close cooperation
with the Technical University of Sofia.
1. Formal energy policy was adopted by management, which stated its clear commitment
to the implementation of specific energy conservation measures for the increase of
energy performance.
2. Clear energy management duties were delegated to the Environmental Manager and to
other company’s staff that affects energy consumption significantly.
3. The announcement of energy consumption results to machine operators, with the use
of graphs every month was introduced. Six month reports were forwarded via e-mail, to
company’s executives with comparative data from the previous period.
4. Energy monitoring was intensified and new more accurate specific energy consumption
indicators were introduced. Instead of monitoring energy per ton of product, energy
was monitored per m of product, thus providing more accurate estimates and
conclusions.
5. Energy conservation and management issues were included at the company’s training
program. Personnel was taught why and how to save energy in everyday operations.
6. Energy performance criteria were adopted in the procurement of all kind of equipment
and in the hiring of external services.
By implementing the above measures, the company raised its energy management
performance to maximum in all significant parameters, thus achieving an average
performance of 4 out of 4.
One important benefit from the pilot implementation was the adoption of new more accurate
energy consumption indicators. Specific energy consumption used to be monitored in
kWh/kg of produced yarn, while the monitoring in kWh/m of yarn proved to be 12% more
accurate. At the next graph differences between respective differences between energy
consumption estimates and true values are presented. The use of indicators based on (m)
of produced yarn allows the implementation of tighter control limits that lead to more
accurate and prompt response.
250,000
200,000
150,000
100,000
50,000
0
Dec-05 Feb-06 Mar-06 May-06 Jul-06 Aug-06 Oct-06 Nov-06
-50,000
-100,000
-150,000
However the use of both indicators shows that during January, September and October
significant deviations from the estimated values appear, this means that energy
consumption during these months should be examined further. Despite the deviations from
the linear estimate of the specific energy consumption in relation with (m) of the yarn
produced, it is clear that significant economies of scale exist. The next graph provides
respective picture.
0.106
0.104
0.102
y = -5E-10x + 0.1126
R2 = 0.3102
0.100
0.098
0.096
0.094
15,000,000 20,000,000 25,000,000 30,000,000 35,000,000
Specific energy consumption at VARVARESSOS S.A. varied between 0.095 and 0.105
kWh/m of yarn and presented clear economies of scale. Average specific energy
consumption is 0.10 kWh/m and the standard deviation around 0.003, about 3% of the
average. In general the overall energy performance is good but there is always potential for
improvement.
The actions that took place within the pilot implementation were:
• Initial Energy Audit, including the Energy Management Matrix;
• Check up off all energy legislation applicable to the company. CITEVE and Vale de
Tábuas defined a search methodology and created a file to register the future
legislation;
• Inquiry to all the company employees, which aimed to know if the employees were
sensitized with energy losses in the company;
• Setting up an action plan and energy policy.
The energy audit identified a current energy consumption pattern, energy management
status, compliance with energy legislation and personnel sensitization to energy issues.
Fabric dyeing
Yarn dyeing
Fabric printing
The energy rationalization plan included many measures, among them the minimization of
compressed air leaks, the optimization of energy monitoring by the installation of special
measuring devices, the repair of old boilers and economizers, the applicability check of the
electricity provision contract, the reactive power minimization, the insulation of pipes and
the legislation compliance check. The implementation of the energy management practices
led to an overall energy conservation of about 5%. A Case Study about the pilot
implementation was prepared and the mains conclusions were:
- Reduction of energy consumption and costs;
- Development of energy management tools;
- Work methodologies creation, in order to contribute to energy consumptions
rationalization;
- Knowledge acquirement, in order to be independent from external energy consultants;
- Mindset changing’s;
- Workers involvement in the energy efficiency;
- Centralize information regarding data treatment and monitoring;
- Creation of new performance indicators.
The elements that contributed to the success of the energy management system
implementation in Vale de Tábuas were:
- Company’s interest;
- Availability, collaboration and dedication of company’s workforce;
- Positive attitude of the company’s team in this entire process, as well as in the data
availability which allowed the system implementation;
- Active involvement of CITEVE’s specialists, which allowed the know-how transfer and
the implementation of energy management tools.
Within the pilot implementation, an energy conservation action plan was realized, leading to
the following interventions:
- Introduction of control systems for non desired electric consumption: Excess of power,
reactive and electricity consumption in non productive hours.
- External systems for analysis of leakages and measurements of energy efficiency; water
and steam leakages internal control system. Currently savings on air leakages were
estimated to be 30.000 €/year.
- Replacing cc engines by asynchronous engines with variable speed drives.
- Distribution of three-phase 380 instead of 220 in oldest facilities.
However the most important energy investment implemented at the factory was the
installation of vacuum tube solar collectors, aiming to the minimisation of the energy
dependence from Natural Gas of Textiles Mora S.A.L. Vacuum tube solar collectors were
installed, due to the fact they are ideal for use in the temperature range 60º to 90º C, as
without concentration they are the only type that can reach these temperatures and also
offer the best quality-efficiency-price ratio. The following Table 15 presents the amount of
thermal energy produced monthly by the solar collectors in comparison to the actual needs
of the industrial processes.
Table 15 –Thermal energy produced compared to the thermal needs of Textiles Mora SLA
This measure decreased the annual consumption of Natural Gas by 75%. The realization of
the investment was followed by a thorough energy monitoring system and the appointment
of an energy manager.
The type of energy mainly used was electricity. For the level of production during the last
two years the annual energy consumption varied from 120 000 to 150 000 kWh. Due to the
fact that the production consists of different types of yarns and textile materials, the specific
energy consumption has been determined, as follows:
Yarns – between 0,1165 kWh/m to 0,17 kWh/m (5 120 kWh/ton to 7 400 kWh/ton)
Textile material – between 0,535 kWh/m to 2,31 kWh/m.
The need for energy use rationalization was large and therefore the restructuring of
production departments, the adoption of energy policy, the installation of energy monitoring
equipment, the implementation of energy conservation training and the procurement of
energy efficient equipment were decided.
In order to improve the existing situation, the following measures had to be applied:
A plan for restructuring of the departments has been developed. A reduction of the
production units in compliance with the real production has been proposed.
Energy policy has been developed, which stated clear commitment to the
implementation of specific energy conservation measures for the increase of energy
performance.
Energy monitoring is intended and new measuring devices are to be installed after the
reconstruction. In relation with this, specific criteria for benchmarking are to be
developed in compliance with the variety of the production.
Training on energy conservation and management issues is to be conducted by the
end of June 2007.
The energy performance criteria that have been developed will be applied in the
coming procurement of equipment for the restructuring.
The implementation of these measures led to an energy conservation of about 14%.
The evaluation of the project’s actions and thus the investigation of the degree of
effectiveness of the activities elaborated within EMS - Textile, compared to the targets set,
was realised via the use of the following two tools:
2. The Project’s Monitoring and Evaluation System, which was prepared with the use of
Microsoft Excel® software, at the beginning of the project and constituted, throughout
it’s elaboration, the tool for monitoring the progress of the each Work Package and it’s
deliverables.
The number of answered questionnaires that were collected was 173. This number
exceeded the objective of answers that had been placed by the beginning of the project
(160). The results of the completed questionnaires are presented in the following Table 16.
Answers
Question Consid Not Don’t
A lot Little
erably at all know
1. How important is energy conservation to your
103 56 10 1 3
company?
2. How much do you think that energy
management can contribute to energy 75 91 3 0 3
efficiency?
3. How useful do you find actions for the
56 98 16 1 2
promotion of energy management?
4. How useful is the publication of articles for
40 59 57 6 11
the promotion of energy management?
5. How useful is network cooperation to the
42 66 31 3 31
promotion of energy efficiency?
6. How useful is the publication of leaflets and
42 75 39 6 11
of good practice guides?
7. How important is website creation for the
55 101 16 0 1
information of interested parties?
From the analysis of the answers of the EMS – Textile’s questionnaires derived the
following conclusions:
2. A very high percentage of the questioned correlate energy management with energy
efficiency. Taken into consideration that Energy Management Systems (EMS) are not
widely know, this high percentage is indicative of the promotion of the concept and
the positive effects of EMS via the implementation of EMS – Textile.
relative sectors.
2%
The network was
expanded to all the participating countries and remains the critical mass for the
project’s information dissemination. 62% of the interviewed seem to recognise the
significant role of setting up networks for promoting energy efficiency and
consequently energy management systems and for their advertising. Conversely,
18% are unaware of the influence a network may have on this type of advertising and
publicity for energy efficiency.
4. Another deliverable developed within EMS – Textile was the operation of the Textile
Energy Offices. The positive role of their operation was recognized as 69% of the
questioned consider useful the operation of help – line desks promoting energy
43%
A lot
Considerably
26% A little
Not at all
Don’t know
12%
9%
10%
5. 89% of the companies interviewed consider that the elaboration of pilot energy
management implementations contribute to the promotion of such systems in the
textile industry. It is obvious that the results of the four pilot implementations that took
place at Greece, Spain, Portugal and Bulgaria, contributed to their acceptance.
Projects like EMS – Textile, used for transferring know - how to businesses, are more
efficient when they
10. How useful is the elaboration of pilot energy
make intensive use management implementations?
activities were highly accepted since nearly 80% characterise both the quality of the
publications and the informative activities very positive.
8. The active participation of companies from all participating countries and their
intention to participate in future actions or exploit the deliverables of EMS – Textile,
are indisputable proofs of the potential of the work done and the infrastructure
produced, ensuring the future impact of the project’s outcomes.
A more analytical presentation of the methodology and the outcomes of the evaluation
procedure are available at Project’s Evaluation Report (Deliverable D.7.4).
The globalisation of the economy and the dynamic inversion of China in the textile market,
have threatened the existence of many Greek textile companies. In their effort to survive
and face this situation, they do not easily proceed in new investments, even when most
estimates favour them and small payback periods are foreseen. Except in the cases of the
dyeing and finishing facilities, the rest textile operations do no consider energy conservation
as a top priority.
5. The relative small size of the Greek textile industries, which doesn’t allow them to
adopt Management Systems. As mentioned before, the preservation of such Systems
requires both human and material resources, and even Environmental Management
Systems according to the ISO 14001:2004 Standard or EMAS Regulation are not
widely implemented, since the public is not acquainted to them and consequently does
not demand them. Many times companies that use it, advertise it as a quality standard
which is more known to the public. Environmental labels, like Eco-label or Eko-tex,
have a little more demand. For the aforementioned reasons, the development of an
Energy Management System is often considered as a task that is not worth much effort
or commitment.
6. The relative small short-time percentage of energy saving. The implementation of
Energy Management Systems results in an annual energy conservation percentage
between 2 – 5%, which is considered very satisfactory in long terms. Nevertheless a lot
of executives tend to consider rather law the annual energy saving and the respective
monetary savings.
7. The relative low price of power in Greece, of the cheaper in Europe.
8. The lack of recognition of the positive effects (those derived from the adoption of
Energy Management Systems) from the owners, managers and key executive
personnel of the Greek textile industries. In some cases this could be characterised as
lack of vision or very conservative approach on further development under the new
status of globalization.
4.1.2 Factors that could promote the development of Energy Management Systems
The elaboration of the current project has contributed into distinguishing the following
factors that could be proven decisive for the further promotion of the adoption of Energy
Management Systems, not only at the Greek Textile Sector but generally at the Greek
Industry:
Preparation on behalf of the Greek State of a specific Legislative Framework that will
enhance energy minimisation and monitoring.
Provision of financial motives to industries that perform an overall good performance on
energy consumption and control, based on officially approved methodologies,
benchmark data and certified procedures.
Operation of the Greek Energy Market on a liberated basis, ensuring healthy
competition and high quality services.
In Portugal al the “Energy Intensive Consumers” have to comply with the Regulation for
Energy Consumption Management (RGCE), which forces the companies to realize energy
audits and implement energy conservation measures. This regulation is applicable to all
industries that are characterised as ‘’Intensive Consumers’’ i.e. companies that:
- their energy consumption during the last year was higher than 1000 toe (tonne oil
equivalent)/year;
- The nominal energy consumption for the total of their equipment is higher than 0,5
toe/hr;
- At least one equipment has nominal consumption of energy higher than 0,3 toe/hr.
All industries considered energy intensive consumers (among them the majority of the
Portuguese textile industries) are obligated to conduct an energy audit every five years.
During this period they must monitor and track energy costs and consumptions, and
implement good practices to reduce the energy consumption.
In Portugal, having in account the data of the two bigger Inspection and Certification bodies,
the approached number of textile companies with ISO 9001:2000 and ISO 14001:1996-
2004 certificated are 222 and 24, respectively. As Energy is an aspect of the implemented
Environmental Management Systems, the above companies have developed procedures
related to monitoring energy consumption or even implementing energy efficiency
measures.
Nevertheless the relative small size of the textile industries doesn’t allow them to adopt
additional Management Systems. The preservation of such Systems requires both human
and material resources, and since even Environmental Management Systems according to
the ISO 14001:2004 Standard or EMAS Regulation are not successfully implemented, it
was very difficult to achieve further results related to energy management.
The aforementioned factors explain the low applicability of energy management in general.
It is evident though that the existing legislative framework – which is adequate – in
combination with state financial aid and the wide presentation of the positive results of the
energy conservation practices will contribute a lot to the further promotion of the effective
elaboration of energy management systems.
On the other hand, there are companies that continue using equipment which, although
functional, is not state-of-the-art and thus the energy consumption is not optimised. Such
companies are the most proactive in terms of the management of energy consumption, as
long as it does not require extra cost or the engagement of human resources. These
constrictions derive form the significant current crisis in the textile sector.
The results obtained by AITEX in terms of the use of renewable energy sources at the
textile sector, in order to generate electricity and hot water for use in industrial processes,
are worth special attention. Studies were carried out, including the implementation of pilot
trials, presenting the steps that should be taken in the future by the companies that are
most advanced in terms of energy management. The methods and technologies examined,
can give companies independence from the unstable energy generation markets which rely
on limited, traditional fuel sources (oil, gas, nuclear energy,…) becoming more expensive
day by day.
Energy conservation and management are relatively new features in the Spanish industrial
sector. Since Spain has to reach the targets that the country committed to in the Kyoto
Protocol regarding energy generation from renewable energy sources, both national and
regional governments now set aside funds to subsidise facilities of this type as much as
possible, aiming to decrease the energy investment pay back periods between 30 and 40%.
The renewable energy technologies that were analysed within the framework of the EMS-
Textile project were:
- Solar Thermal Energy: Especially useful for companies that dye and finish textiles, as
well as for those that consume a lot of hot water and thus have bigger energy saving
potential. The performance of the new vacuum collectors in solar heat panels
indicated that process temperatures can be reached, depending on the speed that
water flow rate at the panels. Savings in the consumption of gas to heat water can
reach up to 60%. This percentage refers to companies located in the Region of
Valencia, where there are almost 300 days of sunshine per year.
- Use of biomass as a fuel to heat water: This technology is an ideal solution for the
same type of companies as the previous option. The efficiency and the operational
range of the current biomass boilers permit the use of different types of fuel (forest
waste, almond shells, olive stones, etc). As they do not rely on a single fuel type,
different options can be used according to their availability during the different
seasons of the year. This means that the fuel is exceptionally cheap and will never
run out, and high temperatures can be reached, with almost no limitations. However,
a minimum amount of auxiliary fossil fuel may be required.
- Photovoltaic Thermal Energy: This energy type is ideal for companies that consume
high levels of electrical energy such as spinning and weaving plants for both
openwork and interlock fabrics. The adoption of this kind of renewable energy
technology can make an industry independent in terms of its energy use. Although
manufacturing companies will only be partially independent, currently the most
important advantage of this type of energy is the possibility of selling the energy
generated to the manufacturing company itself for more than 400% of the value of the
tariff that the power company charges. This illogical situation is also explained by the
need to meet the criteria established in the Kyoto Protocol. As a result, although this
technology can be used to supply electricity for manufacturing processes, it is not yet
being used for this purpose.
4.4.3 Ways and actions for promotion of Energy Management in the industry
Establishment of cost reflective (market) prices of energy and energy carriers. For the
time being the prices of energy and energy carriers achieved market oriented levels
and are already powerful tool to increase the implementation of more energy efficient
approaches in industry.
Establishment of legislative framework. The legislative framework at present is clearly
established and well developed. There are well developed mechanisms for auditing of
enterprises, certifying of buildings, and labelling of products and equipment. The main
activity towards legislation at this moment is to keep the legislation framework up to
date with all relevant EC Directives and to develop advanced norms, standards and
energy indicators.
Awareness campaign and education. New energy management tools and methods are
necessary to be developed/disseminated among the users. Knowledge about modern
metering, information, communication, control and monitoring systems shall be spread
out among textile company managers and energy departments through training
courses, workshops, seminars, brochures, Internet etc.
Creation/availability of funding mechanisms. At present, there are reliable sources for
funding of all activities, related to the energy efficiency. There is a Fund for Energy
Efficiency that supports measures and activities towards increasing the energy
efficiency. The Kozloduy International Decommissioning Support Fund (KIDSF) has
been established and administered by the European Bank for Reconstruction and
Development (EBRD). EBRD gives the sufficient credit lines to the local banks to give
credits to support the energy management activities.
The National banks themselves with their own credits play important role in financing
the measures related to energy efficiency. The availability of credit lines however is not
sufficient condition for implementing energy management projects. The reason is that
most of the textile enterprises can not overcome the initial investments in order to
implement efficient Energy Management Systems and relatives projects.
A Third Party Financing mechanism is appealed do help in overcoming this gap.
Although the Energy Efficiency Law lay down the rules concerning the energy services
and particularly the ESCO, considerable efforts are needed to promote them through
simplifying the rules and disseminating information.
4.4.4 Conclusions
The work performed by BSREC and AATEB during the project implementation allows
formulating the following general conclusions:
The limited implementation of Energy Management in the textile industry in Bulgaria
is a result mainly of the historically established conditions of subsidized prices, poor
economic conditions, lack of normative framework, absence of awareness and
funding sources. The conditions have been improved considerably during the last
several years. It is expected that after the accession to the EU, the economy
development will progress at higher pace.
The energy intensity of the textile industry in Bulgaria is significantly higher than the
same indicator in the EU.
Due to the insufficient awareness about the real possibilities of the EMS approach
and the potential of savings, contrary to expectations the textile companies in very
rare occasions are the active side looking for EM systems implementation.
5 GENERAL CONCLUSIONS
General conclusions that have derived from the realization of EMS – Textile are presented
below:
Many industries in European Union have already undertaken energy efficiency
investments, but the improvement of energy management is not among their priorities,
in many cases because they are not aware of its benefits and practices.
Real management commitment is the key for the successful implementation of energy
management. It is expressed via the allocation of adequate financial and human
resources and not just by written policies.
Many textile companies are reluctant to implement energy management because their
financial situation has worsened view of competition from low cost Asian rivals.
Financial incentives and Third Party Financing are additional options that can be used
in combination with other supportive measures. Experience from the funding of energy
efficiency and RES investments is very positive.
Various energy management schemes have been implemented in Europe for decades.
Some of them focus on energy audits, others on monitoring and targeting, and others
on personnel training and sensitization. More integrated approaches follow the Plan –
Do – Check – Act cycle and are quite similar to ISO 14001. Currently the most popular
and promising trend is energy performance benchmarking, which presents difficulties
due to the lack of precise, analytical and valid data.
Although the average 1.5% of annual energy conservation, due to good energy
management, may appear small, nevertheless it can climb up to an accumulative
conservation of about 15%, after 10 years of continuous implementation. Furthermore
clear task assignment, good internal communication, personnel involvement and close
energy use monitoring, improve significantly the whole management of a company.
These issues have already been outlined during the EMS-Textile project and in its
informative activities.
The fluctuating high fuel prices and global warming are problems that indicate the
significance of Energy Conservation and Management. However, the intensive
economic competition and the lack of financial and human resources in many
companies, make it more difficult. In this controversial environment, all key actors and
stakeholders should try to contribute as much as they can in energy efficiency. Now the
need of cooperation between EU and state officials, energy specialised companies and
industrial enterprises, appears more important than ever