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A QUICK REFERENCE GUIDE

BEST PRACTICES
FOR ENERGY
EFFICIENCY
A summary of ANN INC.s observations from Apparel Manufacturers in China, Hong Kong and Vietnam.

BEST PRACTICES FOR ENERGY EFFICIENCY

ANN INC.

Energy efficiency practices in the apparel industry are rising in popularity in recent years. With surging commodity and
labor costs, better energy management can provide opportunities to deliver cost-savings in manufacturing facilities and
lead to a more sustainable business.
ANN INC. is proud to provide a quick reference guide covering the basics of green practices at apparel facilities, and
share case studies from factory visits and energy efficiency seminars held in China, Hong Kong and Vietnam during 2011.

Lets start from the basics:


(A) KEEP TRACK OF ENERGY CONSUMPTION PATTERNS
Nothing can be done unless you know whats going on inside the facility!
Start off by installing measuring devices (i.e. timers, thermostats) on heavy duty machines.

(B) REGULAR CHECK-UPS ON PIPES


Leaky pipes with insulation coatings that are falling off or are damaged consume a
lot of extra energy! Proper maintenance on pipes ensures efficient use of energy without
compromising the operating costs.
(C) KNOW MORE ABOUT YOUR EMPLOYEES
How much do they know about energy-efficiency? Are they willing or able to help the facility save costs?
Conduct regular check-ups on the work floor:
o Are any devices frequently left idle for over 15 minutes?
o Are any devices being misused by workers?

BEST PRACTICES FOR ENERGY EFFICIENCY

ANN INC.

One step further from the basics:


Having internal or external experts conduct a gap assessment in energy consumption helps you better understand the overall
situation inside the facility. Once data is captured and any energy consumption gaps are identified, then its time to set clear
goals and objectives on energy consumption and practices.

Assess energy
consumption
(internal/
external
assessment)

Efficient
Compare
with actual
energy needs

Satisfactory

A big gap

Further research & development

Organization
getting ready
to change

Define
problems

Long-term goals

Determine
best
strategies

Energy Efficiency: Best Practice Recommendations


SHORT PAYBACK PERIODS
WHAT?

HOW?

SUCCESSFUL CASE STUDIES

Adjustable low-watt

Main source of light coming

Facility type: Womenswear i

LED light bulbs on sewing

from sewing machine instead

No. of employees: ~9000

machines

of from the ceiling


Cost: 4.91 USD per
LED light bulb (1 Watt)
Benefits:

50% ceiling lights

usage
Payback period: 6 months

Short-term goals

Energy Efficiency: Best Practice Recommendations


SHORT PAYBACK PERIODS (CONT.)

WHAT?
Steam after-use recycling

HOW?

SUCCESSFUL CASE STUDIES

Steam after-use can be either

Facility type: Knit ii

(1) fed back to the steaming

No. of employees: ~1000

pipeline for ironing, or

Spin-Dryer Timer Switch

(2) concentrated in hot water

Cost: 6,500 USD per installation

tanks to heat water for domestic

Benefits:

use (dormitory and cafeteria)

Payback period: 6 months

Precise control over drying time

Facility type: Sweaters i

37% of steam after-use waste

No. of employees: ~1000


Cost: 100 USD per switch
Benefits:

0.6% energy wastage

Payback period: 3 months

iii

Boilers using environmentally-

Fuel comes from local

Facility type: Denim

friendly fuel

resources, ie. coconut shells/

No. of employees: ~2200

rice husk/ biomass fuel

Type of fuel: Biomass


Cost: ~50,000 USD per boiler
Benefits:

18% coal use

Payback period: 4-5 months

Energy Efficiency: Best Practice Recommendations


MODERATE PAYBACK PERIODS
WHAT?

HOW?

SUCCESSFUL CASE STUDIES

Energy efficient sewing machines

No energy is consumed when

Facility type: Woven iv

using servo motor

not in use; requires 1/5 of

No. of employees: ~300

sewing thread needed


compared to old models

Cost: ~850 USD per machine


Benefits:

67% energy use


25%-30% productivity

Payback period: 1.5 years


Automatic cutting table

Efficient fabric-cutting, minimizes

Facility type: Woven i

fabric waste due to human

No. of employees: ~9000

factors
Cost: 115,000 USD per unit
Benefits:

10% fabric wastage

Payback period: 1.8 years


Solar water heating system

Use of solar energy to

Facility type: Back pack i

heat water

No. of employees: ~500


Cost: 4,600 USD per unit
Benefits:

50-60% energy use

Payback period: 4.5 years


Water showering ventilation

Keeps the facility cool and

Facility type: Denim (China)

system

maintains desirable humidity by

No. of employees: ~2,200

iii

drawing in fresh outdoor air to


pass through water showering

Cost: varies with factory size

system

Benefits:

80% air-conditioning cost

Payback period: at least 4 years


*A demonstration project under Cleaner Production Partnership Programme by Hong Kong Productivity Council

BEST PRACTICES FOR ENERGY EFFICIENCY

ANN INC.

Lighting Efficiency Special: Systematic Management


Switching traditional light tubes/bulbs to more energy efficient models is usually the first energy efficient practice
adopted by apparel manufacturers. To strive for better results, lighting for different areas of the work floor should
be taken into consideration as their needs will vary. For example, corridors and workzones located by windows
require less lighting than sewing and QA areas.

DIFFERENT LIGHTING NEEDS FOR DIFFERENT AREAS


Corridors

Work zones by the


windows (sunny day)

Sewing & Assembly

Quality Assurance

Find out if the current lighting management is compatible with the specific needs of each area at your facility!

Some Suggestions for Better Lighting System Management


1. INDEPENDENT LIGHT SWITCHES
FOR EACH WORK STATION
Educate workers to be responsible
for switching off the lights when they
leave the work station

2. REFLECTOR COVER ENHANCES


LIGHT CONCENTRATION AND
MINIMIZES DISPERSION OF LIGHT

3. LIGHT- DETECTION: SMART LIGHTING CONTROL*


Install in work zones with less frequent use
Saves electricity automatically by:
(i.e. corridors, product transition zones)
o switching lights off when it is bright
o switching lights on when it is dull or dark
*Suggested by Hong Kong Productivity Council - Cleaner Production Partnership Program

BEST PRACTICES FOR ENERGY EFFICIENCY

ANN INC.

Suggested organizational structure to implement and maintain green practices


Board of Directors

Determine best strategies

Report and review past action plans

Provide support and recognition

Propose new action plans/changes


to current action plans
Seek advice on best strategies

Energy Efficiency Team


(from various departments)

Energy-efficiency
Professionals

Conduct regular check-ups on progress

Advise best strategies

Offer trainings on practices

Implement best practices

Encourage employees to provide feedback


Provide frequent feedback
Help implement and maintain tools

KEY FACTORS FOR SUCCESS:


Support from top management
Set specific, quantifiable and
reachable goals
Embrace team to help execute

Employees

BEST PRACTICES FOR ENERGY EFFICIENCY

ANN INC.

Time to get it started!


Adopting energy efficiency tools on the work floor is definitely not an easy task. The effort, dedication and the cost of
implementation should deliver big wins for your business.
And there is no better time to start than now.

Lets work together and protect our planet!


i
ii
iii
iv
v

Extracted from Factory sharing session during Energy Efficiency Seminar (Hong Kong, China), March 2011
Extracted from Factory sharing session during Energy Efficiency Seminar (Ho Chi Minh City, Vietnam), October 2011
Extracted from Factory sharing session during Energy Efficiency Seminar (Shanghai, China), October 2011
Cleaner Production Partnership: Successful Cases (Textiles)- available in Chinese only
http://www.cleanerproduction.hk/b5_case4.asp?id=257&cid=1&cid2=5&cid3=13
Cleaner Production Partnership: Energy Saving Technologies- Lighting system - available in Chinese only
http://www.cleanerproduction.hk/b5_technology4.asp?id=144&cid=2&cid2=7&cid3=14

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