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Electricity savings at Modern Garments in Mayapuri Industrial Area, New Delhi

Introduction

Development in India is shaped by an advancing industrialisation. The risks associated with industrial development include increasing pollution levels, overuse of natural resources, and increasing amounts of waste and wastewater, that could lead to endangerment of ecosystems.                             

The objective of the “Sustainable and Environment-friendly Industrial Production (SEIP)”project of the Indo-German Development Cooperation is that private and public sector actors jointly implement strategies to achieve an efficient, environment- and climate-friendly industrial development. The implementation of the SEIP project works along three fields of action, which are:

  • Environmentally oriented modernisation of industrial areas.
  • Creation of enabling framework conditions.
  • Knowledge management and dissemination.

The Targeted Area: Mayapuri Industrial Area

The Mayapuri Industrial Area of the Delhi State Infrastructure & Industrial Development Corporation (DSIIDC) is situated in the South West District of the National Capital Territory of Delhi. It is one of the three industrial areas in Delhi selected to showcase concrete solutions of how industrial water pollution can be reduced. The industrial area covers an area of 188 ha housing about 9,361 commercial units of different sizes and sectors. About 2,800 of them are micro-, small, and medium-sized manufacturing industries. 51 of them are classified as seriously polluting by the Central Pollution Control Board (CPCB). The manufacturing industries are from a wide range of sectors including engineering/fabrication, electroplating, pickling, metal finishing, plastic recycling, moulding, oil processing as well as offset printing.

In general, the SMEs do not have adequate environmental management systems in place. Waste and wastewater are often not adequately treated, and raw materials, water, and energy are consumed inefficiently further leading to avoidable waste and environmental pollution. SMEs lack the technical information as well as the knowledge about Best Available Techniques and Technologies in the Indian or international context.

Case Study: Modern Garments -- Energy Savings

Modern Garments, a company engaged in the textile sector, which is located in the Mayapuri Industrial Area of Delhi took initiative to make its operations more sustainable by increasing its energy and resource efficiency. With the support of an Indo-German expert team, an assessment of their current resource and energy usage has been undertaken in order to identify existing efficiency gaps.

Whilst the detailing of measures is currently still ongoing, some success has already been realised through the implementation of simple and low-cost measures related to electrical lighting systems.

Problems identified

Measures (Solutions) 

Costs

Results

Energy Efficiency:

High electricity consumption from inefficient lighting fixtures

(fluorescent tubelights, 11 nos. of 40 W each)

Replacing the existing fluorescent 40 W tubelights with 18 W LED tubelights

INR 4,400 

Electricity saving of around 580 kWh per year, annual monetary savings of around INR 4,645 

Total costs:

INR 4,400

Total monetary savings:

INR 4,645 saved per annum + light replacement less frequently

Estimated payback period:

11 Months    

Measure:

After an Indo-German expert team conducted a comprehensive energy audit at Modern Garments, a high electricity consumption from inefficient lighting fixtures at the electrical panel was identified. The industry was using fluorescent tubelights (11 nos. of 40 W each) at the shop floor. Only by replacing the existing fluorescent 40 W tubelights with 18 W LED tubelights, Modern Garment will be able to achieve electricity savings of up to 580 kWh per year. These energy savings translate into direct economic benefits of around INR 4,645 per year. Apart from electricity saving, the intervention also leads to improved lighting at the shop floor. Another positive result is the longer working life of present light fixtures, which helps reducing purchase cost of tubelights as replacement intervals become longer.

Lesson Learned:

Despite the openness of Modern Garment towards environmental improvements in their operation, there was a scope of amelioration regarding saving potentials within the company. Energy wastage occurred largely because of a lack of knowledge and awareness, and not because of the absence of highly complex technology. Only by information given by the Indo-German expert team about low/no cost saving measures Modern Garments could achieve notable energy and consequently cost savings. Because of the benefits achieved by using the LED lights Modern Garments was encouraged to implement other low/no-cost measures, such as using water from the last rinse for the first rinse at the same batch of denims.

The fact that cleaner production is not merely a good deed for the environment but also helps to increase operational efficiency leading to cost-savings and increased competitiveness, is being vividly demonstrated by the implementation of these simple yet effective changes, further contributing to a change in perception regarding environment-friendly production, paving the way for more large-scale interventions in future by Modern Garments.

                                                                         New LED fixtures 

"Information about existing efficiency gaps in our processes and the implementation of measures that help overcome those inefficiencies allowed us to increase savings and at the same time improve our environmental performance. Not only by using LED lights, but also by applying further measures such as reusing already used water in the last rinse containing chemicals from former production steps, we could bring about positive change within our company. As a smaller amount of water is being required, the storage tanks have to be refilled less frequently what constitutes resource and time savings.“

 
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