Waste Minimization in Textile Industry

Waste Minimization in Textile Industry

Waste Minimization in Textile Industry

Introduction

Waste is a common problem throughout the companies comprising the chemical process industries as well as textile industry also. It is especially a concern to these who manage solid waste, wastewater systems, and hazardous waste or air pollution control devices - typically systems for handling 'end-of-the-pipe' wastes.

Regardless of its type, waste is almost always composed of purchased raw materials that did not become part of a final product. For example, some chemical manufacturers, such as liquid latex producers, have found that their wastewater stream is a dilute form of their primary product. Much of this waste is the result of process inefficiencies that cause entrapment and loss of raw materials. These are conventionally disposed through equipment cleaning. However rethinking and improving process design, piping and vessel design and material-handling techniques can improve process efficiency. The result is reduced waste generation, reduced operating costs, cleaner equipment and increased profits.

A Closer Look at Cleaning

In process industry, equipment is cleaned to remove residues that have a negative effect on the final product or cause production problem. For instance, batch mixing consumer product, such as a water-soluble liquid laundry detergent. may leave a viscous residue that is incompatible with the next product due to colour, content, pH or other properties. Process equipment is washed to remove residues to the point that the amount left in the system will have a negligible effect on the next product.

Flushing the equipment once with water may remove 90% of the residue; and flushing again may remove 90% of the remaining residue, leaving only 1 % of the original contaminant.

Additional washing removes more residues, but at some point the equipment is clean enough to produce the next batch. Additional washing, at this point, only increases downtime, labour costs and water use and wastewater-treatment costs. The goal of cleaning is not to leave the equipment perfectly clean (which is impossible to achieve, in any case), but to remove only as much contaminant as is necessary to cause the process or product to function as required. Some manufacturers have found that eliminating cleaning steps cause no product or process problems.

Doing the Math

Residual costs

Improved Equipment Design

Piping

Rough Connections

Dead Ends

Spill Guards

Recycled Spillage

Smooth Surfaces

Slippery Coatings

Smarter Scheduling

Chemical Compatibility

Energy Efficiency

Revised Runtimes

Filling and Transferring

Reducing Spills

Unused Product

Weighing Method

Bottoms Up

Return Policy

Too full Drums

Involuntary Bonuses

Self Cleaning and Recycled Waste

Pigging Out

Recycling Wastes

Paint Thinner

Training, Procedures And Tools

Informing Operators

Equipping Employees

Troubleshooting Workers

Waste Treatment and Disposal

Reducing Water Usage

Interpreting the Results

Counter flow

Hazardous and Toxic Products

Alternative Solvents

Fringe Benefits

Aqueous Formulations

Conclusion

Waste increases operating costs. This is only part of the cost however for environmental reporting. In fact cradle to grave often known as Life Cycle Analysis, responsible for waste and lost productivity can cost much more to process industries. In terms of productivity, the work needed to make up for the loss should be considered, because the plant would have to operate few additional days annually to compensate the loss if industry is conscious. The waste minimization techniques often considered the best tool for pollution control at source and to improve not only productive but enhance compliance status from environmental angle.

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