HAMS Fashion Ltd. Sustainability Report ( )

Transcription

1 HAMS Fashion Ltd. Sustainability Report ( ) Prepared by Md. Riyajul Haq, Asst. Manager (Environment & Chemical) HAMS Group January

2 Introduction EXECUTIVE SUMMARY Hams Fashions Ltd, leading screen printers in Bangladesh, starts its journey almost 15 years back. It can produce various type of print with optimum quality. The types of production activities are Laser print, pigment print, rubber print, pu print, Plastisol print, Glitter print, High Density print, Silicone gel print, Photo print, Discharge print, Metallic, print, Spray print, Engrave print, Foil print, Stone setting and Flock print. HAMS Fashion Ltd. has been working to adopt & implement various strategies and an approach towards sustainability. As part of this work, water consumption, waste wastewater generation and energy consumption are recorded. Besides, greenhouse gas emission and solid waste inventory are maintained. The water & energy consumption, waste generation and greenhouse gas emission are reviewed by the authority of HAMS Fashion Ltd through sustainability report which is drafted yearly. The authority of HAMS Fashion Ltd sets target and define strategies to reduce water & energy consumption as well as to improve environmental performance. Water consumption Record The source of water for HAMS Fashion Ltd is underground water. The main purpose of water metering system is; to track & measure total water withdrawal from underground, total water consumption for production and the total wastewater generation from HAMS Fashion Ltd. Energy Consumption & GHG emission Record In textile, energy is an important component and without this textile industry cannot be operated. Energy resources are limited and these must be used reasonably and responsibly. HAMS Fashion Ltd mainly uses diesel for generating power & purchase electricity is also used from REB. Table: GHG emission record from HAMS Fashion Ltd in 2016 GHG Emission Summery Direct emission (stationery Indirect emission (purchased Total in Year fuel combustion) electricity consumption) tco2e Production, Solid waste record, ETP outlet water quality & sources of air emission The production activity of HAMS Fashion Ltd is printing of finish garments specially. The production record is maintained in pcs but to convert in weight, every pcs is considered equivalent to 150 gram. Hazardous waste: Iron+Tin+Steel, Wastage oil, Chemical Drum and Medical waste. Non Hazardous waste: Cartoon The solid waste generated from HAMS Fashion Ltd is segregated with 5 classes. Only one item was found nonhazardous waste namely cartoon and others are hazardous. 2

3 Table: Solid waste record of 2016 Year Non Hazardous waste in kg Hazardous waste in kg Total Solid waste in kg Air emission inventory is presented in table-5. Air emission inventory is maintained annually. The air emission test is conducted by third party annually for HAMS Fashion Ltd. There is no accredited body in Bangladesh for air emission test. That s why third part air emission test results are not presented in air emission inventory. The amount of wastewater generation from HAMS Fashion Ltd is negligible. That s why, there is no separate ETP for HAMS Fashion but the wastewater of HAMS Fashion is sent to HAMS washing & dyeing s ETP for treating purpose Target Setting & Action Plan HAMS Fashion Ltd. sets target to improve environmental performance as well as reduce energy & water consumption. The concern authority review improvement against target annually and take corrective action plan to achieve target. Action plan to reduce energy consumption: Upgrade generator monitoring to electrical power management control system, Install solar panel and Use LED & Energy saving Light. Action plan to reduce water consumption: Rain Water Harvesting, Awareness & Monitoring and Reuse/Recycling wastewater. The chemical management system will be formulated and it will work through Plan-Do- Check-Act framework. Conclusion Table: Production, water & energy consumption and wastewater generation in 2016 Year 2016 Production(MT) Water consumption(l) Waste water(l) Energy consumption(mj) Table: Base year water & energy KPI for per ton production Year Base year 2016 Target year 2018 Water consumption (L) 80.9 Reduce by 10% from base year Energy consumption (MJ) Reduce by 5% from base year 3

4 Table of Contents Executive Summery 2 Introduction 5 Water consumption Record 6 Energy Consumption & GHG emission Record 6 Dyeing Production, Solid waste record, ETP outlet water quality & sources of air emission 7 Target Setting & Action Plan 10 Conclusion 15 Acronyms and Abbreviations EMS BMD GJ MT GHG ETP COD BOD TDS TSS Environmental Management System Bangladesh Meteorological Department Giga Joule Metric ton Green House Gas Effluent Treatment Plan Chemical Oxygen Demand Biological Oxygen Demand Total Dissolved Solid Total Suspended Solid MLSS Mixed Liquor Suspended Solid SV SVI F/M REB Sludge Volume Sludge Volume Index Food to Microorganism Rural Electrification Board KWH Kilowatt Hour LED Light Emitting Diode 4

5 Chapter 1 Introduction The textile & garment industry has become the backbone of the economy of Bangladesh. About three million people are involved with garment and textile industries. It is essential to promote sustainability in this large industrial sector. When the world textile & garment market and companies are focusing on environment friendly products, the Bangladeshi garment and textile industries are far beyond of it and it poses a risk of losing the world market. It is high time to adopt special strategies and an approach towards sustainability. Hams Fashions Ltd, leading screen printers in Bangladesh, starts its journey almost 15 years back. It can produce various type of print with optimum quality. The types of production activities are Laser print, pigment print, rubber print, pu print, Plastisol print, Glitter print, High Density print, Silicone gel print, Photo print, Discharge print, Metallic, print, Spray print, Engrave print, Foil print, Stone setting and Flock print. Manufacturing environment friendly products in a sustainable way is the most important and emerging issue at the present phase of industrialization. The main focus comprises not only to the products quality sustainability but also it focuses on the manufacture processes including raw material resources from cradle to grave. Nowadays many companies and organizations focus on the environment friendly way of production. Sustainability of the textile & garments industry is also a burning issue, needed to adopt cleaner and improved technology and management for better environment. Despite the significant economic contribution of the textile industries in Bangladesh, it has brought with it a range of environmental problems, mostly pollution of water resources of the country, energy resources degradation/co 2 emission & eutrophication. Water is very important resources in our ecology. In textile, water is an important component and without this textile industry cannot be operated. Huge quantity of water is used specially in dyeing & washing section. Water & energy resources are limited and these must be used reasonably and responsibly. HAMS Fashion Ltd. has been working to adopt & implement various strategies and an approach towards sustainability. As part of this work, water consumption, waste wastewater generation and energy consumption are recorded. Besides, greenhouse gas emission and solid waste inventory are maintained. The water & energy consumption, waste generation and greenhouse gas emission are reviewed by the authority of HAMS Fashion Ltd through sustainability report which is drafted yearly. The authority of HAMS Fashion Ltd sets target and define strategies to reduce water & energy consumption as well as to improve environmental performance. Based on water & energy consumption data of 2016, the authority of HAMS Fashion Ltd sets three years long target to improve environmental performance. It should be mentioned here that HAMS Fashion Ltd was shifted in current potion in 2015 and production has been starting from November,

6 Chapter 2 Water Consumption Record HAMS Fashion Ltd has installed water metering system to track & measure total water consumption from natural resource and wastewater generation from manufacturing of products. The activity within HAMS Fashion Ltd is printing of finish garments. Most of the water is used for production & domestic purpose. The source of water for HAMS Fashion Ltd is underground water. The main purpose of water metering system is; to track & measure total water withdrawal from underground, total water consumption for production & domestic purpose and the total wastewater generation from HAMS Fashion Ltd. The water consumption record for total water withdraws from underground and the wastewater generation records are presented in table-1: Table-1: Water consumption record in 2016 Water consumption & Wastewater generation in m 3 for HAMS Fashion Ltd-2016 Month/Year Total water Wastewater consumption generation January February March April May June July August September October November December Total HAMS Fashion Ltd has been starting production from November, The water record for domestic is not available due to lack of metering system. Chapter 3 Energy Consumption & GHG Emission Record In textile, energy is an important component and without this textile industry cannot be operated. Energy resources are limited and these must be used reasonably and responsibly. HAMS Fashion Ltd mainly uses diesel for generating power & purchase electricity is also used from REB. The diesel consumption record and the amount of electricity used from REB are presented in table-2. 6

7 Table-2: Energy consumption record of HAMS Fashion Ltd. Energy Consumption record in 2016 Month/Year Diesel (L) Electricity (KWH) January February March April May June July August September October November December Total Total in GJ Diesel & electricity from REB are recorded in litter & KWH respectively. All of these energy units (litter & KWH) converted to common unit GJ using the following conversion factors: Diesel/fuel oil: 43.1 MJ/liter Electricity (KWH): 3.6 MJ/KWH Table-3: GHG emission record from HAMS Fashion Ltd in 2016 GHG Emission Summery Direct emission (stationery Indirect emission (purchased Total in Year fuel combustion) electricity consumption) tco2e Chapter 4 The record of Production, waste generation, ETP outlet water quality & sources of air emission The production activity of HAMS Fashion Ltd is printing of finish garments specially. The production record is maintained in pcs but to convert in weight, every pcs is considered equivalent to 150 gram. 7

8 Table-4: Production record for 2016 Month name Production in Pcs Production in MT January 3,070, February 3,315, March 2,527, April 2,501, May 4,764, June 6,929, July 3,535, August 5,227, September 2,966, October 6,301, November 6,441, December 10,218, Total 57,800, Solid waste: Waste is any substance or object which is discarded, intended to be discarded or is required to be discarded. Waste can include expired raw materials generated from a process for which there is no further use on-site, expired finished products, process or non-process by-products, customer returns, redundant equipment, etc. "A hazardous waste is a waste that could cause harm to public health and/or the environment because of its chemical, physical or biological characteristics (e.g., it is flammable, explosive, toxic, radioactive, or infectious). Hazardous wastes that is dangerous or potentially harmful to our health or the environment. Hazardous wastes can be liquids, solids, gases, or sludge. They can be discarded commercial products, like cleaning fluids or pesticides, or the byproducts of manufacturing processes. (The U.S. Environmental Protection Agency). Table-5 presents the amount of solid waste including hazardous & non-hazardous was generated from HAMS Fashion Ltd. Table-5: Solid waste record in 2016 Year Non Hazardous waste in kg Hazardous waste in kg Total Solid waste in kg Hazardous waste: Iron+Tin+Steel, Wastage oil, Chemical Drum and Medical waste. Non Hazardous waste: Cartoon The solid waste generated from HAMS Fashion Ltd is segregated with 5 classes. Only one item was found nonhazardous waste namely cartoon and others are hazardous. 8

9 Air Emission Inventory: Air emission inventory is presented in table-6. Air emission inventory is maintained annually. The air emission test is conducted by third party annually for HAMS Fashion Ltd. There is no accredited body in Bangladesh for air emission test. That s why third part air emission test results are not presented in air emission inventory. Table-6: Air emission Inventory S.l.No EMISSION POINT NAME OF POLLUTANT SOURCE/ EQUIPMENT EMISSION AMOUNT (AND UNITS) LEGAL EMISSION LIMIT(DoE) MONITORING FREQUENCY 1 Diesel Generator NOX Generator N/A 200 (mg/nm3), DoE Standard Annual 2 Diesel Generator Sox Generator N/A 0.14 ppm 24 hrs & 0.03 ppm annual Annual 3 Diesel Generator CO Generator N/A 9 ppm 8 hrs & 35 ppm 1 hr Annual In-house laboratory wastewater test report: The amount of wastewater generation from HAMS Fashion Ltd is negligible. That s why, there is no separate ETP for HAMS Fashion but the wastewater of HAMS Fashion is sent to HAMS washing & dyeing s ETP for treating purpose. Almost all kind of parameter like as COD, BOD, TSS, ph, TDS, MLSS, SV, SVI, F/M can be analyzed by ETP laboratory of HASM washing & dyeing. The activity of this laboratory was started from March, In table-7, only ETP outlet water test results are presented. Table-7: ETP outlet water quality test report (In house laboratory) Date COD in BOD in ppm TSS in ph ppm ppm 6/4/ /4/ /4/ /4/ /4/ /4/ /4/ /5/ /5/ /5/ /6/ /6/ /7/

10 26/7/ /8/ /8/ /8/ /8/ /9/ /9/ /10/ /10/ /10/ /11/ /11/ /12/ /12/ Chapter 5 Target Setting & Action Plan HAMS Fashion Ltd. sets target to improve environmental performance as well as reduce energy & water consumption. The concern authority review improvement against target annually and take corrective action plan to achieve target. Energy Target Name 5% energy consumption reduction for per ton production Target Type Normalized Base year 2016 Target Start date 01/01/2017 Target End Year 31/12/2019 % Reduction from base year N/A Metric for Normalized targets per ton of production Base year consumption amount MJ The current reporting period's normalized N/A energy consumption amount Water Target Name 10% Water consumption reduction for per ton production Target Type Normalized Base year 2016 Target Start date 01/01/2017 Target End Year 31/12/2019 % Reduction from base year N/A Metric for Normalized targets per ton of production Base year consumption amount 80.9 L The current reporting period's normalized N/A energy consumption amount 10

11 Chemical management Target Name Achieve 80% score in chemicals management performance in selfassessment module Target Type Absolute Base year 2016 Target Start date 01/01/2017 Target End Year 31/12/2018 % increase chemicals management N/A Performance score from base year Metric for Absolute targets Total score in self-assessment module Base year score 35% The current reporting period's score N/A Action Plan: Energy: Upgrade generator monitoring to electrical power management control system Projection Time: 2017 to 2018 The present generator monitoring provides too little information for monitoring their performance. Fortunately a better generator monitoring system is available. However even this system can be improved and extended as to include real-time diesel consumption and overall generator efficiency along with the complementing power consumption from the grid. By installing an electricity measuring system for generator and by upgrading this monitoring system to calculate effective efficiency at varying load and adding automatic modulating controls a true electrical power management system can be realized automatically control all generators which switches the generators on/off according to demand and optimizes the production of each generators as to achieve maximum the overall efficiency while minimizing the total cost of power consumption including grid and stand-by diesel generators. Install solar panel: Projection Time: 2017 to 2019 The authority of HAMS Fashion Ltd has a planned to use solar panel for lighting purpose to save energy as well as reduce carbon foot print for entire factory. Use LED & Energy saving Light: Projection time: 2016 All lights of entire factory of HAMS Fashion Ltd are LED & energy saving light. The authority of HAMS Fashion Ltd uses LED & energy saving light for lighting purpose to save energy as well as reduce carbon foot print. 11

12 Water: Rain Water Harvesting Projection Time: 2017 to 2018 HAMS Fashion Ltd has a plan for rainwater harvesting on roof top area of the shads & buildings. Table-8 presents the roof top area of the shads & buildings with the annual volume of rainfall. From figure-1, it can be seen that the lowest annual rainfall is 4.4 mm in January and the maximum annual rainfall is mm in July. In average, at Dhaka & Gazipur region, the annual rainfall is 1960 mm from 2001 to Figure-1: Monthly averages of Rainfall & Humidity data at the Dhaka & Gazipur region (From Dhaka BMD Station), Source: Bangladesh Meteorological Department Table-8: Roof top area of the shads & buildings with the yearly volume of rainfall Building/shad Area in m 2 Annual average rainfall in mm Volume of rainfall (Annual) in m 3 Main Building Office Building Total tool use to convert rainfall in mm to rainfall in m 3 considering roof top area) From table-8 it can be seen that, HAMS Fashion Ltd can use approximately 2536 m 3 water annually from rainwater harvesting instead of using from ground water. According to figure- 1, the maximum possible rainfall is 388 mm (4817 m 3 for area of m 2 ) in July throughout the year. Reuse/Recycling wastewater Projection time: The authority of HAMS Fashion has planned to reuse/recycle wastewater by installing proper treatment process. The description of propose treatment process is given below: 12

13 Waste water from production floor come into collection tank where waste water is becomes homogeneous mixture by aeration. From collection tank waste water is sent to reactor tank where, firstly this waste water is mixed with PAC solution by agitator. After 20 minutes, polyelectrolyte is added to reactor tank and agitates this mixture for 40 minutes. After completion of reaction, agitator is kept in stop mode for 30 minutes to settle sludge. After settling sludge, 60/50% clear water from upper level of reactor tank is sent to aeration tank and 40/50% water with sludge from the lower level of reactor tank is shifted to sand filtration bed. From filtration bed, water is shifted to equalization tank. After 60 minutes aeration, clear water from aeration tank can be used for screen washing purpose. Figure-2: Process flow diagram of proposed HAMS Fashion waste water pretreatment process Awareness & Monitoring Projection time: 2017 to 2018 The significant amount of water consumption for dyeing & washing section can be saved by monitoring & creating awareness. Turn off Running Taps and Hoses This simple procedure can result in substantial savings. People are often unaware of the cost of leaving taps and hoses running. They are more likely to turn off running taps and hoses if they are made aware of the annual cost of waste. Meanwhile, fixing hand triggers to hoses is a simple way of reducing water use and saving money. 13

14 Turn off Water when Machines are not running. Encourage workers to turn off machines and water during breaks and at the end of the day. Avoid circulating cooling water when machines are not in use. The concern department of HAMS Fashion Ltd has been working to formulate & implement an integrated Environmental Management System (EMS). A relevant program for creating awareness & monitoring regarding water consumption will be included of that EMS. Improve chemicals management performance: The concern authority of HAMS Fashion Ltd. committed to: Continual improvement of chemical management performance Expand win of economic, environmental, safety & health and organizational benefits through implementing systematic management of chemicals Complying with national legislation and conforming to emerging customer requirements and international standards on management of chemicals strengthening in-house competence of personnel in companies (workers, middle management), integrating CM training into in-house training units enabling EHS managers/officers and company personnel concerned with handling of chemicals in textile companies to improve the condition of chemical management in the factory The chemical management system will be formulated and it will work through Plan-Do- Check-Act framework. The following jobs will be conducted through Plan-Do-Check-Act framework to establish an appropriate chemical management system: Maintaining legal register including National and other laws and regulations Systematically identify and document chemicals used and stored Material flow accounting; Process flow diagram, Chemical trajectory & NPO identification Maintaining Chemical inventory Chemical risk analysis Hazard & risk mapping Chemical risk management action; Training, Document Development, Document and Record Control, Chemical Management Work Practices & Emergency Procedures; Exposure control measures, Safety data sheet management(procedure for making SDS available), Chemical handling( procedure for SOP development, format), Chemical storage in well design store, Chemical transportation, Chemical use Regular and optimization, Personal protective equipment (procedures for selection, use, maintenance), Laboratory practices, Maintenance and housekeeping, Waste and disposal. 14

15 Chapter 6 Conclusion The total production (MT), water (m 3 ) & energy (GJ) consumption and wastewater (m 3 ) generation in 2016 of HAMS Fashion Ltd. are presented in table-9. Table-9: Production, water & energy consumption and wastewater generation record of HAMS Fashion Ltd. in 2016 Year 2016 Production(MT) Water consumption(l) Waste water(l) Energy consumption(mj) Figure-3: presents the production, water & energy consumption and wastewater generation of HAMS Fashion Ltd in 2016 Table-10: Base year water & energy KPI for per ton production Year Base year 2016 Target year 2018 Water consumption (L) 80.9 Reduce by 10% from base year Energy consumption (MJ) Reduce by 5% from base year 15 Signature Authority