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Sustainable engineering solutions for resource efficiency, profitability, and environmental impact.
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Garment Manufacturing Facility, Bangladesh
A large-scale CMT garment manufacturing plant with 100 steam irons and a 1.5 TPH boiler suffered from utility inefficiencies. Venting flash steam, leaking distribution valves, uninsulated pipelines, and inefficient clutch motors led to high natural gas and electricity waste.
A comprehensive energy audit was conducted and 12 clean energy measures were implemented: Flash Steam Recovery, Condensate Recovery, Steam Line Leak Repair, Piping Insulation, TDS Blowdown control, Steam Saving Irons, Generator Exhaust Gas Boiler (EGB), Flue Gas Condensing Economizer, Servo sewing motors, Direct-Drive Fans, LED Lighting, and Compressed Air leak repair.
High Pressure iron discharge collected
Vessel separates steam and condensate
Exchanger preheats boiler feedwater up to 90°C
Boiler fuel consumption reduced by 6%
Captures generator waste heat to produce process steam, saving $86,519/year with a 17-month payback.
Recovers heat from 140°C boiler exhaust to preheat feedwater, saving $41,726/year.
Replaced 100 conventional irons, cutting steam use per iron by 50% and saving $25,177/year in fuel costs.
Comprehensive project balancing high-investment recovery vessels with low-cost distribution leak repairs.
| # | Measure | Investment | Annual Savings | Payback | Impact Scope |
|---|---|---|---|---|---|
| 1 | Flash Steam Recovery System | $5,000 | $3,115 | 19 months | 12,596 m³ Gas (6%) |
| 2 | Condensate Recovery System | $5,000 | $2,713 | 22 months | 1,200 m³ Water (48%) |
| 3 | Distribution Leak Repairs | $200 | $2,778 | 1 month | 11,220 m³ Gas (6%) |
| 4 | Steam Piping Insulation | $775 | $958 | 10 months | 3,881 m³ Gas (1%) |
| 5 | Boiler Automatic TDS Blowdown | $1,646 | $796 | 25 months | 3,215 m³ Gas (1%) |
| 6 | Steam-Saving Sewing Irons | $8,228 | $25,177 | 4 months | 102,000 m³ Gas (50%) |
| 7 | Generator Exhaust Gas Boiler | $120,000 | $86,519 | 17 months | 297,939 m³ Gas (9%) |
| 8 | Boiler Flue Gas Economizer | $70,000 | $41,726 | 20 months | 169,046 m³ Gas (11%) |
| 9 | Sewing Machine Servo Motors | $12,342 | $4,937 | 30 months | 48,000 kWh (50%) |
| 10 | Direct-Drive Exhaust Fans | $19,220 | $7,900 | 29 months | 76,800 kWh (36%) |
| 11 | LED Lighting Retrofit | $3,168 | $1,620 | 23 months | 15,750 kWh (36%) |
| 12 | Compressed Air Leak Repair | $2,500 | $4,465 | 7 months | System leaks closed |
Adjust parameters to estimate savings for your facility
