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.

Let’s start from the basics:

(A) KEEP TRACK OF ENERGY CONSUMPTION PATTERNS
• Nothing can be done unless you know what’s 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 it’s time to set clear
goals and objectives on energy consumption and practices.

Efficient Further research & development Long-term goals

Assess energy
consumption Compare
(internal/ with actual Satisfactory
Organization Determine
external energy needs Define
getting ready best Short-term goals
assessment) problems
A big gap to change 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
Energy Efficiency: Best Practice Recommendations
SHORT PAYBACK PERIODS (CONT.)
WHAT?
Steam after-use recycling
Spin-Dryer Timer Switch
Boilers using environmentally-
friendly fuel
HOW?
Steam after-use can be either
(1) fed back to the steaming
pipeline for ironing, or
(2) concentrated in hot water
tanks to heat water for domestic
use (dormitory and cafeteria)
Precise control over drying time
Fuel comes from local
resources, ie. coconut shells/
rice husk/ biomass fuel
SUCCESSFUL CASE STUDIES
Facility type: Knit ii
No. of employees: ~1000
Cost: 6,500 USD per installation
Benefits: 37% of steam after-use waste
Payback period: 6 months
Facility type: Sweaters i
No. of employees: ~1000
Cost: 100 USD per switch
Benefits: 0.6% energy wastage
Payback period: 3 months
iii
Facility type: Denim
No. of employees: ~2200
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?
Energy efficient sewing machines
using “servo motor”
Automatic cutting table
Solar water heating system
Water showering ventilation
system
HOW?
No energy is consumed when
not in use; requires 1/5 of
sewing thread needed
compared to old models
Efficient fabric-cutting, minimizes
fabric waste due to human
factors
Use of solar energy to
heat water
Keeps the facility cool and
maintains desirable humidity by
drawing in fresh outdoor air to
pass through water showering
system
*A demonstration project under Cleaner Production Partnership Programme by Hong Kong Productivity Council
SUCCESSFUL CASE STUDIES
Facility type: Woven iv
No. of employees: ~300
Cost: ~850 USD per machine
Benefits: 67% energy use
25%-30% productivity
Payback period: 1.5 years
Facility type: Woven i
No. of employees: ~9000
Cost: 115,000 USD per unit
Benefits: 10% fabric wastage
Payback period: 1.8 years
Facility type: Back pack i
No. of employees: ~500
Cost: 4,600 USD per unit
Benefits: 50-60% energy use
Payback period: 4.5 years
iii
Facility type: Denim (China)
No. of employees: ~2,200
Cost: varies with factory size
Benefits: 80% air-conditioning cost
Payback period: at least 4 years
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 Sewing & Assembly Quality Assurance
windows (sunny day)

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 2. REFLECTOR COVER ENHANCES

FOR EACH WORK STATION LIGHT CONCENTRATION AND
• Educate workers to be responsible MINIMIZES DISPERSION OF LIGHT
for switching off the lights when they
leave the work station

3. LIGHT- DETECTION: SMART LIGHTING CONTROL*

• Saves electricity automatically by: • Install in work zones with less frequent use
o switching lights off when it is bright (i.e. corridors, product transition zones)
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 Energy-efficiency

(from various departments) 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

KEY FACTORS FOR SUCCESS: • Help implement and maintain tools

• Support from top management

Employees
• Set specific, quantifiable and
reachable goals
• Embrace team to help execute
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.

Let’s work together and protect our planet!

i Extracted from Factory sharing session during Energy Efficiency Seminar (Hong Kong, China), March 2011
ii Extracted from Factory sharing session during Energy Efficiency Seminar (Ho Chi Minh City, Vietnam), October 2011
iii Extracted from Factory sharing session during Energy Efficiency Seminar (Shanghai, China), October 2011
iv 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
v 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