Energy and Water Efficiency Audit at a Dyeing Unit

The Nishat Mills is a dyeing and finishing unit of a composite textile mills in Pakistan. This unit expressed its need for improving energy efficiency in its equipment and industrial processes. The dyeing unit had already undergone a walkthrough audit, which revealed significant savings potential in water, steam and electricity. The IFC was looking for a firm to carry out a detailed energy and water audit at the industrial facility. The project was supported by International Finance Corporation (IFC) Advisory Services – Middle East and North Africa (MENA), a donor-funded program covering 19 countries and managed by the IFC regional office in Cairo.

Econoler was commissioned to carry out an in-depth assessment to determine energy and water efficiency potential at the dyeing and finishing unit. To achieve this goal, the EE technical experts conducted a preliminary desktop review, a site visit and a detailed data analysis, as summarized below:  

• A preliminary desktop review and prioritization of opportunities based on key operational parameters as identified in the walkthrough audit by making a comparison with best practice benchmarks and standards.
• A site visit for collecting comprehensive baseline data and information about the unit’s operations, products and resource utilization; measurement of key parameters to assess energy and water efficiency levels.
• A review of the industry baseline and equipment performance, including operation and maintenance practices, flow diagram for each process, energy balance, and pattern of energy and water consumption.
• A benchmarking analysis of plant performance by looking at similar plants and best available international technologies applied to the textile sector.
• A cost/benefit analysis to prioritize efficiency opportunities, provide a comprehensive analysis of performance improvement projects (expected earnings, required investments and cost-effectiveness) to identify modifications in current plant layout, and energy and water savings and CO2 emissions that could be avoided.

  A comprehensive energy audit report was prepared and presented to IFC and the Nishat Mills representatives in a PowerPoint presentation. The report enabled the beneficiary to identify the most cost-effective priority EE measures and take the required actions to achieve energy savings forecasted.