NAME OF BEST PRACTICE:

BATinLoko – Environmental performance indicators and their relation with economic factors in textile BAT implementation

Current contact: Maria José Carvalho
Project manager: Dionisia Portela
Fax: +351 25 230 03 17
Email: mjcarvalho@citeve.pt

Website: https://www.citeve.pt/
References: here or here

WHERE: Europe, (Partners From Portugal: CITEVE (Technological Centre for Textile and Clothing Industry); ATP (Textile Association); APA (Government Agency for the Environment); UM (Minho University).
WHEN: Implemented from 2009 to 2011
WASTE MANAGEMENT HIERARCHY: Recycling: Reuse – Reprocessing; Prevention: Replacement – Reduction
TYPE OF INSTRUMENT: Education, information, awareness raising; Regulatory / Normative
WASTE STREAMS: Textiles

 

About: The best practice BATinLoko envisage the implementation of BAT (best available techniques) for companies operating IPPC (integrated pollution prevention and control) systems in order to secure sustainable development approaches to environmental management.
BAT details are explained in brefs (BAT reference documents), which are technical documents that set out the standards required for environmental factors, such as emissions. Bref information about emission requirements for the textile sector is currently not indicated. This can create difficulties for stakeholders during assessment of textile companies’ environmental performance and in identifying methods that can be considered as bat.
The Portuguese textile sector is a major employer and has a key role to play in environmental management. 
The industry is made up of about 2 500 companies (95% are SMEs), of which 36 companies were directly involved in IPPC systems for the pre-treatment or dyeing of fibers or textiles (exceeding 10 tonnes/day).

BATinLoko project

Objectives

The main objective of the BATinLoko life project was to define best environmental performance indicators, with targets, for the textile and clothing sector in Portugal. The methodology would provide a common working tool for obtaining comparable results. The aim was to demonstrate an effective approach that can be flexible and applicable to other sectors across Europe.

Economic factors would be examined to assess the commercial impacts of BAT implementation and an IT tool would be created to illustrate positive and negative impacts in different operational circumstances. A decision support manual was also planned to provide textile companies with appropriate information about environmental performance indicators, economic factors and BAT implementation. Special attention would be paid to preparing advice about reducing carbon footprints and CO2 emissions

Resources

Funding; budget: LIFE 07 env/p/000625
Project reference: LIFE07 env/p/000625
Total budget: 311,955.00 €; EU contribution: 152,752.00 €
Period of implementation: January 2009 to June 2011

Results

A) General results
The project developed innovative tools and proposals for textile companies and stakeholders:
• An economic model for the analysis of economic constraints related to BAT implementation;
• The BATinLoko webtool to simulate the environmental and economic benefits when implementing bat;
• The BATinLoko manual for decision support in bat implementation that presents the environmental performance indicators that are generally more suited to bat performance study and the economic analysis of bat.
• An environmental performance indicators field study was carried out at nine Portuguese textile com-panies. From the data obtained, general environmental performance indicators related to the produc-tion process were calculated. Specific environmental performance indicators for the 12 bats studied were also determined: from the data obtained general and specific environmental performance indica-tors were calculated for the 12 bats studied:
• Heat-insulation of pipes and stenters;
• Segregation of hot and cold waste water streams and recovery of heat from the hot stream;
• Installation of automated dosing and dispensing systems which measure out the exact amount of chemicals and auxiliary required and deliver them directly to various machines through pipework with-out human contact;
• Installation of automated dosing and dispensing systems which meter the exact amount of dyes re-quired(only foreseen for manual operations for dyes that are used infrequently);
• Recovery and reuse of sizing agents by ultrafiltration;
• Enzyme treatment;
• Recovery and reuse of alkali from mercerizing rinsing water;
• Minimising volume capacity of the dip when using pad dyeing techniques, in continuous dyeing pro-cesses;
• Reusing rinse water;
• Reducing water consumption in printing cleaning operations;
• Minimising energy consumption in stenter frames by installing heat recovery systems;
• Elimination of bleaching in dark colors dyeing.
These data served as a basis for the definition of the economic model, as well as for the development of the webtool and the manual. The tools allow different scenarios to be simulated to test a wide range of process variables and quantify the benefits of implementing a given bat using the company’s data processes and/or reference values.
A BAT implementation study allowed participating companies to check, in loco, whether their application is resulting in economic and environmental benefits, namely reductions in water consumption costs, the production and concentration of wastewater, chemical consumption, and operating time, among others. The decision support methodology proposed by the project is, therefore, an added value for companies, since it produces immediate results by calculating the environmental and economic benefits of bat implementation.
A conduct code was also implemented by the beneficiaries to reduce CO2 emissions associated with the project, based on a set of procedures and good practices. During the entire project, the partnership was able to offset 10 tonnes of CO2.
The methodologies and tools developed in the scope of the project can easily be transferred to other companies of the textile sector all around the world. In addition, project results can also be an important contribution to the revision of Bref for the textile industry.
Further information on the project can be found in the project’s layman report and after-life communication plan (see “Read more” section).

B) Quantifiable awareness raising/ media coverage, which led to education in waste management:
The practice clarifies some ambiguities in existing legislation and procedures in view of more effective implementation of environmental legislation. The implementation of these best available techniques is needed by companies operating integrated pollution prevention and control systems in order to secure sustainable development approaches to environmental management.

C) Collected waste/environmental improvement:
The practice propose a strategy that affects an industry made up of about 2 500 companies (95% are smes), of which 36 companies were directly involved in IPPC systems for the pre-treatment or dyeing of fibres or textiles (exceeding 10 tons/day) only in Portugal.

Urban metabolism relevance

The practice is proposed as a regulatory action that assess the textile company’s environmental performance. Like any BAT, regulates the technologies and the maximum quantities of pollutant evacuated. The results of the practice envisage waste management, air quality, health and safety, demonstrate an effective approach that can be flexible and further applicable to other sectors.

The practice is in connection with various energy and material flows, assessing processes as:
o heat-insulation of pipes and stenters;
o segregation of hot and cold waste water streams and recovery of heat from the hot stream;
o installation of automated dosing and dispensing systems which measure out the exact amount of chemicals and auxiliary required and deliver them directly to various machines through pipework without human contact;
o installation of automated dosing and dispensing systems which meter the exact amount of dyes required (only foreseen for manual operations for dyes that are used infrequently);
o recovery and reuse of sizing agents by ultrafiltration;
o enzyme treatment;
o recovery and reuse of alkali from mercerising rinsing water;
o minimising volume capacity of the dip when using pad dyeing techniques, in continuous dyeing processes;
o reusing rinse water;
o reducing water consumption in printing cleaning operations;
o minimising energy consumption in stenter frames by installing heat recovery systems;
o elimination of bleaching in dark colors dyeing.

The strategy objectives follow material flows through actions related to urban metabolism:
o recovery and reuse of alkali from mercerising rinsing water;
o minimising volume capacity of the dip when using pad dyeing techniques, in continuous dyeing processes;
o reusing rinse water; reducing water consumption in printing cleaning operations;
o minimising energy consumption in stenter frames by installing heat recovery systems;
o elimination of bleaching in dark colors dyeing
The practice enhance the circularity of materials, trying to reduce the material quantities used in processes, reduce loses, improve environment, avoid accidents.

Engaged participatory processes

The practice have been elaborated and implemented by research institutes, professional associations, policy makers and have been implemented in the private sector; it has been disseminated in multiple research articles, and press releases, etc. An environmental performance indicators field study was carried out at nine Portuguese textile companies. From the data obtained, general environmental performance indicators related to the production process were calculated.

Innovation

The practice propose some new solutions for improving and calibration process such as:
o Heat-insulation of pipes and stenters;
o Segregation of hot and cold waste water streams and recovery of heat from the hot stream;
o Installation of automated dosing and dispensing systems which measure out the exact amount of chemicals and auxiliary required and deliver them directly to various machines through pipework without human contact;
o Installation of automated dosing and dispensing systems which meter the exact amount of dyes required(only foreseen for manual operations for dyes that are used infrequently);
o Recovery and reuse of sizing agents by ultrafiltration;
o Enzyme treatment;
o Recovery and reuse of alkali from mercerising rinsing water;
o Minimising volume capacity of the dip when using pad dyeing techniques, in continuous dyeing processes;
o Reusing rinse water;
o Reducing water consumption in printing cleaning operations;
o Minimising energy consumption in stenter frames by installing heat recovery systems;
o Elimination of bleaching in dark colors dyeing.

Sustainability and replicability

The project is considered sustainable and effective, being designed an “after-life dissemination plan” and has been implemented in 9 Portuguese textile companies with good results, this creates the premises for a superior replicability of the project. Being a regulatory action can be easily adopted by a company or a public authority, considering the supporting documents.

The practice must be assimilated by textile factories and by regulating authorities. More about the results here

UrbanWINS

Waste, Resources, Innovation.

Key challenges

A specific recommended focus should be on how the social aspects have been tackled / integrated by the tool.

Info

For more information, please check the deliverable, or contact the implementing body.

Click on the green icon on the left side of the page to print and download this Best Practice as PDF.

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