Evaluation Of Energy Conservation Options In Sri Lankan Apparel Industry

By

Chamalie Ahangama Withanage B.Sc (Hons) Facilities Management University of Moratuwa a.w.chamalie@gmail.com Sri lanka

Background
Apparel industry
Seriously affects to the countrys economy Energy intensive industry and energy usage is inefficient Energy cost is a significant component

Energy conservation
Close link to quality and productivity improvements Essential for surviving and enhance this sectors global competitiveness

Aim
Identify energy conservation options and the barriers of energy conservation in practical usage that can be applied on an apparel industry

Objectives
Identify various types of energy conservation options Identify and analyze energy conservation options in apparel industry Ranking the energy conservation options according to the level of importance and comparison with current usage

Identify the barriers of implementing energy conservation options Prioritizing influential (strong) energy conservation barriers

Literature Review
Energy conservation option
Lighting Air-conditioning with HVAC and ventilation Boiler and Steam distribution Compressors/Pumps Sewing/Ironing/Cutting - 14 - 19 - 19 - 19 - 12

Barriers of energy conservation options

Knowledge related factors Cost related factors Organization and employee related factors Technological factors - 07 - 06 - 11 - 07

Research Process
Research problem Background study Establish aim & objectives Literature synthesis Data Collection Preliminary Survey
Guide to sampling and identification options & barriers

Further Research

Sample selection Questioner Survey Data Analysis

Conclusion & Recommendation

Data Collection

Western province BOI approved large scale garments Distributed Questionnaires Responded Questionnaires - 37 - 30

Research Methodology
Questionnaire Survey
Questionnaire one - Usage level of energy conservation options Questionnaire two - Perspective level of energy conservation Questionnaire three - Rank the energy conservation barriers

Statistical Tools
Mean (Wi) - Rank perspectives and current usage Severity Index (S.I) - Significance in affecting energy conservation Percentage of importance - Significance Coefficient of Variation (COV) - Compare relative variability One sample t-test - Identify significant factors Cronbach's Alpha - Reliability of Data

Findings

Energy conservation options

Lighting Air-conditioning with HVAC and ventilation Boiler and Steam distribution Compressors/Pumps Sewing/Ironing/Cutting
Importance 50%-90% Severity index Mean rating 65%-95% Above 3 COV 15%-40%

Significance of factors influencing energy conservation in lighting

No 1 2 3 4 5 6 7 8 9 Factor Energy efficiency in LED lamp Florescent light fitting with high frequency electronic ballast Automatic Scheduling Task light Natural light Maintain correct LUX level in factory Re design/Rearrangement Zoning Mean 3.76 3.57 3.54 3.51 3.38 3.35 3.32 3.30 3.16 3.08 Actual Rank Mean 8 1 7 3 11 5 4 6 2 10 3.59 4.16 3.62 4.03 3.19 3.84 3.95 3.70 4.11 3.27

CFL light Polished aluminium reflectors (mirror 10 reflector) fix to luminaries

Significance of factors influencing energy conservation in Air conditioning

No
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Factor
Control the central A/C system by BMS or CMS Central A/C system Centrifugal chillier VSDs on chilled water pumps Duty cycling System optimization Optimized start /stop Conserve energy using zoning FCU Air curtain Electrical demand limiting Apply sun control films to glass Energy conservation with VAV Energy conservation with variable speed cooling tower Chilled water reset

Mean
3. 83 3.65 3.62 3.59 3.51 3.41 3.38 3.35 3.35 3.32 3.30 3.24 3.16 3.11

Actual Rank Mean

11 6 8 10 1 9 2 7 4 5 3 15 16 14 3.59 3.92 3.73 3.62 4.35 3.70 4.19 3.84 4.11 3.95 4.14 2.84 2.78 3.05

Significance of factors influencing energy conservation in boiler and stream distribution

No
1 2 3 4 5 6 7 8 9 10 11 12 13

Factor
Install efficient burner Duty cycling Furnace oil boiler Pre heat of fuel Air pre heater Steam flow meters Dampers, inlet valves, or variable speed drives Install thermostat Steam trap Recycling of drain Install them heat-insulated Install Time switches Utilization of heat exchanger

Actual Mean Rank Mean

4.35 4.14 4.11 4.03 3.95 3.92 3.84 3.73 3.70 3.59 3.41 3.19 3.05 7 2 16 9 12 11 10 14 8 1 3 17 19 3.41 4.11 2.57 3.11 3.05 3.08 3.16 2.70 3.27 4.16 4.03 2.41 2.32

Significance of factors influencing energy conservation in compressor and pumps

No
1 2 3 4 5 6

Factor
VSD (Compressor) VSD (Pumps) Pressure optimization Compressor selection Minimize air leakage Capacity bank

Actual Mean Rank Mean

3.86 3.70 3.62 3.46 3.41 3.27 9 6 1 2 3 7 2.68 3.39 3.84 3.68 3.66 3.37

Significance of factors influencing energy conservation in sewing

No
1 2 3 4 5 6 7 8 9

Factor
Stepper motor Direct drive server motor Intelligent motor controllers for sewing machines Full steam iron Mini trap Gubber cutter Capacity bank Control maximum demand Maximisation of utilisation

Mean
4.19 4.11 3.95 3.92 3.84 3.62 3.59 3.41 3.19

Actual
Rank
3 2 12 5 4 9 10 1 6

Mean
3.95 4.11 2.38 3.59 3.76 2.76 2.46 4.16 3.56

Rank Correlation Coefficient

Section
Lighting Air condition Boiler Compressor Sewing

T-Cal
2.658 3.453 0.779 -0.177 0.847

T(28)
2.179 2.110 2.110 2.365 2.228

Factors having highest difference in rankings

Section
Lighting

Factor
Energy efficiency in LED lamp CFL light

Rank Difference Perspective Actual

1 9 5 1 11 4 3 16 17 1 4 2 3 8 12 8 2 11 11 3 10 16 4 5 9 9 6 12 1 7 -7 7 -6 -10 8 -6 -13 12 12 -8 5 -4 -9 7 5

Natural light (Solar light) Air condition Control the central A/C system by BMS or CMS Apply sun control films to glass VSDs on chilled water pumps Boiler Furnace oil boiler Low pressure and large-diameter piping Radial large at bend Compressor VSD (Compressor) Operate in low pressure VSD (Pumps) Intelligent motor controllers for sewing machines Control maximum demand Arranging continuous material flow

Sewing

Barriers of energy conservation

Barriers
Cost Knowledge Technology Organization and employees

Mean Value
3.653 3.347 3.143 3.131

Energy conservation barrier on cost

No
1 2 3 4

Factor
High cost associated with plants and equipments Cost associated with energy conservation technology is considerably high Cost associated with BMS applications which are related to energy conservation is high Have a long investment payback period

Mean
4.11 3.95 3.62 3.41

Energy conservation barrier on knowledge

No
1 2 3 4 5 6

Factor
No champions who can handle energy conservation matters Lack of knowledge about advance management techniques Low technology literacy of employees Low level of adopting new technology Employees in organization are not monitoring international best practices Insufficient assessment of systems prior to installation

Mean
4.16 4.11 3.95 3.59 3.41 3.27

Energy conservation barrier on technology

No
1 2 3 4 5 6

Factor
Allocating funds for energy conservation technologies are not sufficient in organization Rapid change of technologies Hesitating to adopt new technologies to the organization Insufficient technical practice in the organization Have technical problems caused by the unreliability of the technologies Local technical training institutes provide lack of training regarding energy conservation improvements

Mean
4.03 3.84 3.70 3.41 3.08 3.05

Energy conservation barriers on organization and employees

No
1 2 3 4 5 6 7

Factor
Upper Management Support Lack of staff support Vision of the organization providing lack of support to adopt energy conservation option Resistance to change by staff Limited vision Fear of change and uncertainty Funds allocated for employees' training programs on energy conservation are insufficient

Mean
4.16 4.11 3.95 3.62 3.59 3.41 3.27

Conclusions
Lighting section:
LED lamp, Florescent light fitting with high frequency electronic ballast and Automatic scheduling

Air conditioning section:

Control the central A/C system by BMS or CMS, Central A/C system and centrifugal chillers

Boiler and steam distribution:

Efficient burner, Duty cycling and Furnace oil boiler

Compressor and piping:

VSD (compressor), VSD (pumps) and Pressure optimization

Sewing section:
Stepper motor, Direct drive server motor and Intelligent motor control

Conclusions (Cont)
No correlation among the rankings of:
Boiler, Compressor and Sewing sections

Have correlation among the ranking of:

Lighting and Air condition factors

Cost related factors are the largest barriers for the implementation of energy conservation strategy

Recommendation
Eradicate the prevailing negative behavioural and personal attitudes towards energy conservation Convey the message of the importance of evaluation of energy conservation options to survive in the industry Government and external consultants: energy audits should be conducted to identify the key areas Use energy conservation options after an appropriate evaluation

Further Research
Case study can be conducted to check the validity of the proposed energy conservation options introduced by this research Can extend this research to identify the relationship of all the energy conservation options and organization profits This research outcome can be further improved and develop as cost declining tool Can extend this research to other industries (ex. Hotel)

Thank You

Rank Correlation Coefficient

Rank correlation measures the difference between the ranks for each pair
Distributed t with n-2 degree of freedom

rs - Rank Correlation Coefficient di - Difference between each rankings n - Number of objectives

Difference between Ranking

Compressor
The null hypothesis is accepted. According to that there is no relationship between the rankings. Therefore there to a 95% confidence interval it can be stated that the ranking the factors of current usage and experts perspective is different.

0.177

2.365

Data Analysis
Severity Index

(W F ) 100% S.I . =
i i

Fi n Wi

-Frequency of Responses -Total number of responses -Weight for each factor

Coefficient of Variation (COV)

COV S = 100 % X
COV S x

-Coefficient of Variation -Standard Deviation -Weighted mean of sample

No. of respondents + who stated the criteria is Important

Percentage of importance
Percentage =

No. of respondents who stated Significantly Important and Extremely Important

Total no. of respondents