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Textiles: Case Studies
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This sections provides a collection of case studies of textile facilities that have actually implemented techniques and technologies to improve efficiency and reduce waste.

(2000) Brittany Dyeing and Printing Corporation reduces energy consumption and air emissions through use of foam finishing technology.

(1997) Spectrum Dyed Yarns had maximized its water and wastewater capacity as well as its boiler capacity, but needed more capacity to meet increasing production needs, by increasing water use efficiency the company was able to meet increasing production demands while reducing water consumption per pound of product produced. Water usage per pound of yarn dyed, and cost savings calculations are included.

(1997) Renfro reduces the sulfur dioxide (SO2) emissions from its boilers with low-sulfur fuel and reduces chlorine bleach usage from its processes. Price savings of chlorine use reduction are included.

(1996) Nisshinbo California, Inc. (NCI) working with ADI Control Techniques Drives (ADI-CT) of Hayward, California retrofitted 15 of the system's fan motors with variable frequency drives (VFDs). This change enabled the fan control dampers to be fixed in a fully open position, and improved the system's air flow control and energy efficiency.

(1996) DuPont's Cape Fear polyester yarn plant implemented several waste reduction efforts which resulted in significant savings. By changing simple procedures such as sampling, spinning position, and yarn package changes, the facility was able to reduce product waste. Additionally, process modifications eliminated the use of methanol and decreased VOC emissions by lowering process temperatures; waste PET plastic is recycled rather than landfilled; and unused process equipment was turned into a glycol recycling center for DuPont. Waste reduced, annual cost savings, and additional activities are included.

(1996) Hubert Textiles Pty. Ltd. operates a textile dyeing and printing business. Significant cost savings and environmental benefits have resulted from the installation of a computerized paste mixing system. A payback of approximately 2.5 years was achieved through reduced raw material and waste costs and efficiency improvements.

(1996) Springs Industries reduced their solid waste generation through reusable chemical storage containers, recycling, reusable shipping pallets, a switch to a non-hazardous parts washing solvent, waste stream segregation and sizing reuse, and process waste reduction through teams and goal setting. Includes annual waste reduction and savings calculations.

(1995) Guilford Mills determined that the majority of VOCs were emitted during heat setting and printing. VOC emissions were reduced by an average of 67% in 6 plants. Most reductions were accomplished by switching from a solvent based edge gum to a water based adhesive.

(1995) Bloomsburg Mills has actively pursued waste reduction and recycling throughout its production processes, including chemical substitution of their dye carrier with less hazardous chemicals, reusable bulk chemical storage containers, a recycling program, and process heat and water reuse. Calculations of air emissions, and solid waste reduction and associated cost savings are included.

(1995) Hoescht Celanese, which produces polyester fibers, has implemented a corporate-wide program to reduce waste and emissions. Projects include the elimination of trichloroethane used for degreasing, implementation of a leak detection and repair program and a recycling program, and process modification to remove toxic compounds from wastewater, distill them, and use them for boiler fuel. Waste reduction and annual savings calculations are included.

(1995) West Point Stevens successfully implement p2 activities including air emissions reduction; boiler fuel change; energy, water, and chemical use optimization; use of bulk chemical storage containers; recycling; and replacing cardboard spinning tubes with reusable and recyclable PVC cones. Additionally, Westpoint Stevens initiated a chemical approval committee to find alternative, less toxic chemicals for use. Calculations of annual waste reductions and savings are included

(1995) Cleveland Mills implemented a waste reduction program, resulting in significant reductions in wastewater releases, air emissions, and solid and hazardous waste streams. Calculations of formaldehyde, solid waste, and wastewater pollutant reductions are included.

(1995) An integrated textile manufacturer (weaving, dyeing, and finishing) made several changes in its textile manufacturing process to reduce the use of trisodium phosphate, sodium hydroxide, and sodium nitrate. TSP, previously used in scouring, was completely replaced by sodium carbonate. These reductions cut the company's use of toxic chemicals by more than 20,000 pounds per year, saved it $5,000 in chemical purchases and regulatory fees, and enhanced worker health..

(1995) Sara Lee Knit Products Corporation's process modifications to reduce salt, dye, and water usage through process optimization, segregate wastes to allow wastewater reuse, and improve wastewater quality through filtration. Includes annual waste reduction and savings calculations.

(1994) Milliken implemented an extensive environmental program that eliminated use of extremely hazardous chemicals at the facility, reduced the use of hazardous chemicals, reduced solid waste, and reduced energy consumption.

(1994) Skjern Tricotage-Farveri uses an enzyme to replace a chemical agent (such as thiosulfate) in bleach neutralization leading to reduction in water and energy consumption.

(1992) An Australian facility uses environmental management to improves product quality in wool scouring.

(1992) An Australian yarn manufacturing plant uses cleaner production and waste minimization techniques.

(1992) An Australian facility uses cold pad batch dyeing of cellulosic fabrics with fiber reactive dyes to reduce waste and chemical use.

(1992) Cranston Print Works uses cleaner production measures in printing and finishing.

(1992) A Norwegian company producing plastic coated textiles reduces solvent use.


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Hub Last Updated: 3/11/2008