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Energy analysis of a case-study textile mill by using real-time energy data

Conference Paper · June 2014

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Energy analysis of a case-study textile mill

by using real-time energy data

Ali Agha & David P. Jenkins

Urban Energy Research Group
School of the Built Environment
Heriot-Watt University
Edinburgh Campus EH14 4AS
United Kingdom
+44-131-4514447
aqa1@hw.ac.uk

Keywords Introduction
energy efficiency assessment, energy demand, textile manufac- Emerging climate change and sustainability compliance is
turing, peak and off-peak production increasing pressure on businesses to reduce their energy use.
Energy efficiency is one of the most promising ways. In the
case of small and medium enterprises (SMEs) in the indus-
Abstract trial sector, there is a difficulty in studying a large number of
The textile industry has relatively high energy consumption industry-specific technologies of this diverse sector (Energy
compared to other small and medium industries. More energy Research Partnership 2011). Therefore, most of the energy ef-
performance studies are required to improve process energy ficiency practices carried out in the sector are based on com-
efficiency. For any energy efficiency study, measuring the en- monly shared technologies, e.g. air compressors, boilers, etc.;
ergy consumption quantitatively is the first step. This paper this can underestimate the real efficiency potential of a specific
utilises high-resolution empirical energy data of a vertical case industry. Representing a heterogeneous and fragmented indus-
study textile mill to estimate its overall energy use and to find try in the SME sector, textile is a less energy-intensive industry
out any underlying efficiency improvement opportunities. than, for example, cement, steel, chemical, etc. The industry has
Average seasonal load profiles have been calculated against specific characteristics mainly due to multiphase production
shift patterns and weekly and annual consumption trends are processes involving multiple units per phase and each having
investigated. Despite winters being at a time of off-peak pro- different production rates (Karacapilidis and Pappis 1997) and,
duction, heating related gas use was found to be significantly therefore, distinct energy requirements. This aspect of manu-
high during this period, with high specific energy consump- facturing can have a detrimental impact on the total process
tion (SEC) per unit of production. The study identified some energy consumption. However, textile energy studies make up
actionable energy saving opportunities that consisted of re- a relatively small share of all industrial energy studies (Hasan-
ducing the weekend baseline load for both electric and gas beigi and Hasanabadi 2012). More energy studies in this sec-
through behaviour change and simple management. Some tor will help to identify the energy efficiency potential for the
site-specific processes and technology-based energy savings industry itself as well as for the other similar industries.
were also identified. The paper reveals how a more detailed Energy efficiency in a manufacturing environment can be
energy analysis of a process-specific non-domestic building achieved through two aspects: 1)  a system approach, which
(such as a textile manufacturer) can provide much richer and appreciates energy efficiency opportunities lying both in the
actionable information than more standard energy audits and supply chain side as well as on the demand side (mostly outside
surveys. The key methods and techniques used in this analysis the scope of this study), and 2)  a component or technology
are outlined in the paper, such that they may be extrapolated approach which focuses on improving energy efficiency of
to other non-domestic buildings in similar industries. individual technologies. Energy management, for example,

ECEEE INDUSTRIAL SUMMER STUDY PROCEEDINGS  223

2-080-14 AGHA, JENKINS 2. SUSTAINABLE PRODUCTION DESIGN & SUPPLY CHAIN INITIATIVES

may be carried out through equipment efficiency and controls can be from a change in technology, (such as replacement of
development, and through change in behaviour and energy an old iron melting furnace with a new electric arc technol-
culture. These types of energy efficiency improvements are ogy), to technology alteration (inverter drives for motors), or
normally made possible through “Surveys” or “Audits”, which reduction in energy waste (controls on air and steam leaks)
are carried out by consultants and may consist of a one-off or (Gordic et al. 2010). Optimisation studies about production
a continuous improvement plan. Short-term energy audits and systems and process control in SMEs have shown notable ef-
surveys do have limitations, such as only picking up a small ficiency improvement results (Mirade et al. 2012). Several en-
number of improvement opportunities based on a one-off visit, ergy studies in the textile industry have addressed different
but observations based on long-term energy studies can yield aspects, such as energy efficiency in a Toray textile mill case
better results. study (Best practice programme guide 148 n.a., Palainchamy
A different approach is that of Operation and Maintenance and Babu 2005), energy intensity comparisons (Hasanbeigi
(O&M), involving timely maintenance of technology which and Hasanabadi 2012, Ines and Martinez 2010), and energy
encourages consistent efficiency. This might include, for ex- consumed per unit of production of a spinning unit (Koc and
ample, changing the air filters on heating and air conditioning Kaplan 2007). To disseminate the scope of energy efficiency in
units, repairing air and steam leaks, oiling and greasing the this sector, several industry-focused organisations have pro-
moving parts of the machinery. Such a programme generally duced reports (Department of Environment 1997, Hasanbeigi
contains five distinctive components: Operations, Mainte- 2010, United Nations Industrial Development Organisation
nance, Engineering, Training, and Administration, collec- 1992). However, the actual implementation of energy efficien-
tively called “OMETA”. Studies have shown these measures cy measures can lag behind the theoretical calculations due to
working effectively (Richard, n.a.). Implementation of an en- lack of implementation method, and lack of knowledge of the
ergy management system can involve building upon different measures themselves.
steps consisting of energy policy, planning, implementation In this study the total energy use, both for onsite produc-
and operation, checking and corrective actions, and a man- tion and operations, of a textile factory is estimated. Also, the
agement review. The formation of an energy management energy efficiency improvement possibilities have been assessed
standard ISO 50001 which provides a strong organisational therefore the main objectives are;
framework for energy management is another way of imple-
• To identify the major technology used and the potential for
menting it. However, for any energy efficiency study, meas-
energy saving.
uring the energy consumption quantitatively is the first step
(Wang 2012). • To assess the impact of departmental energy consumption
Numerous methods are used to measure and estimate this on the total energy use.
energy consumption. For example, detailed methods for end-
• To determine the effect of off- and on-season production on
use energy consumption estimations in non-domestic build-
specific energy consumption.
ings have been discussed elsewhere (Field at al. 1997, Bryant
and Carlson 2002). An energy audit might be based on year- In the following sections a review of industrial energy, par-
long monthly utility bills or, more reliably, daily demand meter ticularly within the UK textile industry, is taken. The meth-
readings. However, there may be chances of inaccurate estimate ods used for the data analysis will also be described and site-
billing and risk of gaps and human error is involved with man- specific energy efficiency opportunities are discussed. Also,
ual data. Inaccuracy related to estimate billing, for example, can total energy consumption, SEC, and energy trends/patterns
cause ambiguity in industrial energy studies. The use of high- are identified.
resolution automatic meter reading (e.g. every half-hourly for
electricity in the UK) has reduced such risks considerably and
provided an often under-utilised data source. Different visu- Industrial energy and textile case study site
alisation techniques for such short-term time-series data have Industrial energy accounts for one-third of global energy
been discussed in Motegi et al. (Ferreria 2009) and have vari- (Greening and Roop 2007). In the UK, 57 % of industrial en-
ous applications and limitations. For example, Wijk and Selow ergy is used by more energy intensive industries i.e. iron and
(1999) used calendar profiles (cluster and contour plots) to steel, cement, chemical, paper and pulp, etc. (Energy Research
identify consumption trends and patterns on multiple time Partnership 2011). The textile industry in the UK uses 0.4 %
scales (days, weeks, and seasons). Daily profiles (line plots) are of national energy and is responsible for 0.4  % of national
commonly used for time series data and can be used to verify greenhouse gas emissions (Allwood et al. 2006). 70 % of the
operation schedules, identify peak hours, and base load. The industry’s process energy requirement is met by low-grade, be-
technique can lead to better consumption pattern understand- low 200 ˚C, thermal energy which is provided mostly by gas in
ing if the periods to compare are correctly chosen (Stuart et the UK. However, some textile manufacturing processes, for
al. 2007). The analysis based on these plots helped to identify example for synthetic fibres, use more electricity as compared
building system failures and opportunities for energy saving to others processes.
(Ferreria 2009, Kilpatrick 2012). As communication to the The case-study mill is a vertical textile mill, which means
end-user is of paramount importance, reflecting the findings it carries out all the production processes from raw materi-
of such studies should increase the chances of theoretical sav- al finishing to fabric producing onsite. The factory has over
ings becoming reality. 45 buildings with 22,800 m2 treated area. All production de-
Studies focusing on technology aspects have shown effi- partments – Yarn production, Finishing (manufacturing “A”),
ciency improvements in all types of industrial activities. This Dye house, and Weaving (manufacturing  “B”) as shown in

224  ECEEE 2014 INDUSTRIAL SUMMER STUDY – RETOOL FOR A COMPETITIVE AND SUSTAINABLE INDUSTRY
2. SUSTAINABLE PRODUCTION DESIGN & SUPPLY CHAIN INITIATIVES 2-080-14 AGHA, JENKINS

Figure 1, and operations (administration) departments work

alongside each other in the factory. The on-production season Wool  
or “on-season” starts in March and ends in September, and
off-production season or “off-season” starts in October and
ends in February. In other words off-season generally repre-
Dye  house
sents the winter. The operations departments/sections con-
(yarn  and  
sist of information technology office, human resources and
wool  dyeing)
administration offices, customer services, factory retail and
coffee shops, factory warehouse and stock room. These sec-
Manufacturing   Yarn   Manufacturing  
tions work throughout the year, and the holidays are adjusted
(A) production (B)
accordingly. Depending on the amount of work occurring in
the production departments, shown (bold) in Figure 1, this
(Spinning,  
can be completely or partially closed during the holiday pe-
twisting,  and  
riods. Some departments can also undertake night shifts and
texturising)
Saturday overtimes. As mentioned above, such a complicated
work environment makes production processes and energy Weaving  
use more difficult to predict, which is also observed in the en- (yarn  warp  
ergy consumption analysis section. A generalised shift pattern and  wefts  to  
is assumed and shown in Figure 3. make  cloth)
Depending on the nature of the fibre, e.g. cotton, synthetic,
wool, production processes in the textile industry may vary, Finishing
as will the energy demand and type of fuel. In this case, gas (Scouring,  
contributes towards 80 % of the total energy demand, shown sizing,  
in Table 1. It is worthwhile to mention that the factory is lo- pressing,  
cated in the north-east of Scotland, which has a significantly raising)
long and cold winter, the heating period in the factory span-
In  brackets,  single  underlined  text  is  predominantly  gas  based  thermal  energy  and  
ning from early October through to end of May. Addition- double  underlined  text  is  electric
ally, some of the buildings in the factory are up to 200 years
old, and the factory runs a conventional steam heating system Figure 1. Production process flow at the mill.
with a small number of buildings on electric heating. Figure 1
shows the process flow at the case-study mill. Each square
box represents individual production department with the
processes taking place within and are underlined to indicate duction for the year to find out their share of SEC per me-
major fuel type used. tre of production. Time-series electricity profiles (Figure 2)
Two main meters for electricity and gas supply energy to the were constructed which showed a rise (weekdays) and fall
whole factory, with no sub-metering around the production (weekends) in demand. Half-hourly electricity demand data
area in the factory. And the energy demand of individual de- was used to calculate weekday average “on-season” and “off-
partment was estimated through profile analysis. Steam, which season” profiles against generalised weekday shift patterns as
is produced by three conventional industrial boilers with a shown in Figure  3. Sections and departments with similar
capacity of 3,000 kg/h. each, is the main heat carrier for both shift routines were identified and classified into three catego-
production and heating. The other main gas-based technology ries; i) Operations, ii) Manufacturing (A), and iii) Manufac-
is a stenter frame, which consists of three large chambers in turing (B) as mentioned above. A clear variation in energy
which hot air is blown to dry and set the size of the cloth in the consumption followed shift patterns and further analysis of
Finishing section, which is further discussed later. Two com- these profiles confirmed increased energy demand in winter.
pressed air units, 45 kW each (one of which is generally on It also quantified the expected reduction in demand during
standby), are utilised to meet the compressed air demands. The factory holidays. Through the analysis, it was also possible to
other users of electricity are mainly motors, industrial dryers, find base load and manufacturing “B” demand in addition to
lighting, building services and small power and IT (informa- the peak-demand. The estimated gas bills (from the energy
tion technology). supplier) were plotted against the manual data taken from the
main gas meter and the discrepancies investigated (Figure 4).
The gaps in the manual data, particularly for the weekends,
Energy technology and demand analysis were estimated by dividing the consumption with the number
By carrying out a technology audit at the factory, major en- of days within the gap. The SEC was further reviewed on a
ergy user technology was identified. A review of energy ef- monthly basis as shown in Figure 5.
ficiency opportunities for both process and technology based
on industry specific publications and onsite observations is
discussed in the section below. Utility bills data for gas and Energy efficiency opportunities for the case study
electricity for the year 2011 were reviewed and analysed to Possible energy efficiency improvements for the factory are
establish baseline energy use. The individual sums obtained discussed below, with more detailed recommendations given
from these, shown in Table 1, were divided by the total pro- in later sections.

ECEEE INDUSTRIAL SUMMER STUDY PROCEEDINGS  225

2-080-14 AGHA, JENKINS 2. SUSTAINABLE PRODUCTION DESIGN & SUPPLY CHAIN INITIATIVES

BUILDING SERVICES AND IT frame have revealed some potential for improved efficiency. As
Lighting, heating, ventilation, and air-conditioning (HVAC), discussed elsewhere (BREF 2000), optimising the exhaust air
small power and IT equipment, in both the production and moisture, cloth dwell time, and heat recovery from the exhaust
operations departments are significant. All the operations of- air could be explored further. Some manufacturers of these
fices are lit, mostly, with T8 fluorescent tube lights. The pro- exhaust heat recovery systems claim up to a 30 % increase in
duction sheds use T12 8 ft. fluorescent tube lights. Replace- efficiency. The machine also has a 55 kW burner and mechani-
ment of these phased-out fluorescent tube lights with efficient cal motors system and can offer efficiency savings through im-
lighting would be the most obvious recommendation. Most of proved motors and variable speed drives. In addition to the
the production sheds have north-facing roof lights and some technology side, some production process improvements are
buildings are only occasionally used, therefore these build- also achievable. These, according to (GPG 168), may consist
ings would benefit from lighting-level controls and occupancy of revising the dyeing and scouring programmes process times
sensors. The HVAC in most of the buildings is controlled by a and reducing water usage to save overall energy input. Use of
building management system (BMS). The running times and reactive dyes, needing lower temperatures (60 ˚C) for colour
temperature settings on the system have never been changed fixing, and the use of efficient mechanical drying, with suction
since the installation of the system. A critical time and tem- slots, manglers, etc., can greatly reduce the drying energy cost
perature review can help to reduce the HVAC’s running cost. on the stenters.
Also, a thorough review of the motors in the systems can
highlight saving opportunities through proper sizing and Other processes
other measures as discussed below. To reduce the weekend These processes refer to Yarn manufacturing, Weaving, and
baseline load an equipment checklist for each building has the Finishing departments. Technologies in these departments
been designed and is passed on to the designated members of mostly relate to rotation/vibration processes and conveyor
staff to ensure everything is shutdown at the weekends. These belts, and extensively depend upon motors. This is reflected
checklists also include the canteen areas and small power and in the average power factor of the factory at 44 % for March
IT equipment. Numerous guidelines for the IT and building through to July (2012), which is also subject to improvement.
services have been published by energy efficiency focussed These machines are automated and programmed through elec-
organisations e.g. The Carbon Trust, and US Department of tronic controls. Most of the technology in these departments/
Energy (DoE). sections is between 10–50  years old therefore some of these
machines are strong candidates for more efficient motors, for
PRODUCTION PROCESS example as advised by International Electrotechnical Commis-
sion. Motors in some newer machines have built-in variable
Wet processes frequency drives (VFD), and these drives could provide signifi-
These processes mainly involve dyeing in the Dye house and cant savings for some technologies where suitable. Considering
scouring (washing) in the Finishing area. These processes are the age of the technology in the factory, a review of the sizing of
mainly thermal and use steam. The technology used for these the motors is critical and should prove to be a helpful measure
processes is simple consisting of large containers/vessels with for energy saving. Studies on industrial motor energy efficiency
closed coils for the steam flow. Programmable electronic con- have shown considerable potential in this area (McKane and
trol systems are used for water, washing chemical/dyes, cloth Hasanbeigi 2011).
feeding in/out, process temperature and cloth/material dwell
time control. Motors and pumps are used for pumping and UTILITY PLANTS
agitation or some mechanical processes. The average daily de- Compressed air and boiler units are common technologies
mand of the water for the Dye house is 200 m3 and roughly across many different industries, with considerable guidance
30 % of this is used for dyeing process. The dyeing process in in published literature (such as Carbon Trust’s energy efficiency
the factory, starting with water at 50 ˚C, achieves a maximum guides). Air and steam leaks in the distribution systems are the
temperature of 98 ˚C and then the water is discharged with- very first step that could be addressed to improve efficiency,
out heat recovery. The daily water demand of scouring is also and in many cases simple measures like lowering the steam
200 m3 and roughly 40 % of that is used for hot water washing at and compressed air pressure can be quite beneficial. The com-
40 ˚C. This hot water is also directed towards the drain without pressed air units were manufactured in 2008 and can execute
heat recovery, however water at this temperature is generally many energy efficiency features, which have not been fully har-
not suitable for heat recovery. Heat recovery and recycling from nessed. A comprehensive review on achieving energy efficiency
these processes could save significant energy and an account of in compressed air systems is given in (Schmidt and Kelly 2005).
heat recovery methods in thermal processes is given by (Hasa- Boilers also operate 24 hours a day, seven days a week even
nuzzaman et al. 2012). Both processes use hydro-extractors when steam for production or heating is not required; this was
(spin dryers) equipped with heavy-duty motors, 25 kW each, specifically monitored through simple weekend boiler shut-
for centrifugal drying. The energy efficiency opportunities for downs by the author. Detailed studies about improving energy
these motors can be reviewed against the options discussed efficiency in boiler systems (GPG 369) are available for guid-
below. Some microwave and infrared ovens are used for dyed ance. Inbuilt timers on both the boilers and the compressed
raw material drying in the Dye house. Studies have shown this air systems can be utilised to control their weekend/off-peak
type of drying as reasonably efficient (Buyukakinci 2012), but loads to make some simple savings. Also, both the systems are
a thorough study of the operation of the machines could high- a good candidate for exhaust air heat recovery (Hasanuzzaman
light further avenues for savings. Investigations of the stenter et al. 2012).

226  ECEEE 2014 INDUSTRIAL SUMMER STUDY – RETOOL FOR A COMPETITIVE AND SUSTAINABLE INDUSTRY
2. SUSTAINABLE PRODUCTION DESIGN & SUPPLY CHAIN INITIATIVES 2-080-14 AGHA, JENKINS

Energy consumption analysis in winters. Another contributing factor is reduced activ-

Table 1 shows the total energy consumption for 2011. Despite ity in manufacturing (A) as discussed above. These factors
the demand for electricity being only one fifth of the total en- happened to be the major contributors towards increased
ergy, its cost equals to half of the total energy bill. Therefore, energy use and higher production costs in winter season as
even modest electric energy efficiency improvements could discussed in SEC calculations below. The fall of Friday curve
make significant contributions to cost savings. The table also at around 17:30 indicates the baseline demand. In spite of the
shows the SEC which is discussed in detail below. Figure  2 reduced amount of off-season overtime between 06:00–12:00
shows daily electricity consumption with the number of fac- on Saturdays, the curve looks similar to on-season. This also
tory holidays (taken from the factory’s holiday calendar) af- indicates winter related increase in demand and can also be
fecting the monthly demand, indicated with arrows. Reduced observed through increased off-season baseline demand. The
off-season demand can only be seen in October and Novem- reduced demand between 20:00–00:00, for off-season Sunday,
ber. This is when the production activity becomes slow and indicates that only one of the two departments of manufactur-
some sections in manufacturing (A) would either run smaller ing (B) is working.
shifts or go on two-week holidays. The increased demand in The analysis revealed an average peak-time demand be-
December, January, and February, particularly representing tween 850–950 kW whereas for off-peak time it was reduced
the baseline and electric heating demand, indicates winter- to between 250–400 kW for both seasons, which represents the
related consumption. The on-season consumption is consist- demand of manufacturing “B”. The average baseline load was
ently high despite no heating being used from May through found to be 115  kW, which might be considered reasonably
to end of September, indicating a production-related rise in high. The energy trend and patterns assumed through these
demand. There are nine mechanical air handling units, 9.5 kW profiles helped to understand energy consumption on a daily
each, that are used for both heating and cooling in the ma- and half-hourly basis. The in-depth understanding at such a
jor production buildings. There are 10 air conditioning units, resolution was never possible by an ordinary energy survey or
3.5 kW each, in the office buildings around the factory that audit as mentioned above. The analysis also pinpointed some
are used for cooling only. This load considerably contributes areas of energy saving, such as reducing the baseline energy use
towards demand in the summer. that would not have been visible through information collected
In Figure 3, power demand profiles from Monday–Thurs- on a monthly basis.
day are compared and peak-time for off-season shows a Monthly gas consumption, both estimated/invoiced (esti.)
slightly increased demand, attributed to it being winter. How- and manually collected (man.), are shown in Figure 4. In ad-
ever, off-peak demand, from 18:00 to 06:00, in off-season is dition to disagreeing with the manual consumption curve,
relatively low indicating the reduced activity of manufactur- the estimate gas curve is found to be too high for June and
ing (B) as only the Weaving department works night shifts July, indicated with arrows. This was to compensate for the

Table 1. 2011 consumption.

Energy Consumption Cost Specific Energy

2011 utility
MWh/year % £/year % Consumption (kW·h /metre)

Electric 4,147.61 19.69 378,361 48.65 3.68

Gas 16,924.66* 80.32 399,280 51.35 15.00

Total Energy 21072.27 777,641 18.68

* Based on supplier’s estimate invoices.

Figure 2. Daily electricity demand.

ECEEE INDUSTRIAL SUMMER STUDY PROCEEDINGS  227

2-080-14 AGHA, JENKINS 2. SUSTAINABLE PRODUCTION DESIGN & SUPPLY CHAIN INITIATIVES

a. Off-season power demand.

Mon Tue Wed Thu Fri Sat Sun

1100
1000
900
800
Power  (kW)

700
600
500
400
300
200
100
0
01:00

02:00

03:00

04:00

05:00

06:00

07:00

08:00

09:00

10:00

11:00

12:00

13:00

14:00

15:00

16:00

17:00

18:00

19:00

20:00

21:00

22:00

23:00

00:00
i)Operations ↓(1)↓(2)↓(2)↓(4) ↑(1)↑(6) ↑(2)
i)Mfg.  (A) ↓ ↑
i)Mfg.  (B) → →
ii)Operations ↓(1)↓(2)↓(4)↓(2) ↑(2) ↑(1)↑(1)↑(4)↑(1)
ii)Mfg.  (A) ↓ ↑
ii)Mfg.  (B) ↑(DH) ↑(W)
iii)Retail  (R)+OT ↓(OT) ↓(R.) ↑(OT) ↑(R.)
iv)Retail ↓ ↑ ↓(W+DH) →

b. On-season power demand.

Mon Tue Wed Thu Fri Sat Sun

1000
900
800
700
600
Power  (kW)

500
400
300
200
100
0
01:00

02:00

03:00

04:00

05:00

06:00

07:00

08:00

09:00

10:00

11:00

12:00

13:00

14:00

15:00

16:00

17:00

18:00

19:00

20:00

21:00

22:00

23:00

00:00
i)Operations ↓(1)↓(2)↓(2)↓(4) ↑(1)↑(6) ↑(2)
i)Mfg.  (A) ↓ ↑
i)Mfg.  (B) → →
ii)Operations ↓(1)↓(2)↓(4)↓(2) ↑(2) ↑(1)↑(1)↑(4)↑(1)
ii)Mfg.  (A) ↓ ↑
ii)Mfg.  (B) ↑(DH) ↑(W)
iii)Retail  (R)+OT ↓(OT) ↓(R.) ↑(OT) ↑(R.)
iv)Retail ↓ ↑ ↓(W+DH) →

Legend

→ ↓ ↑ i ii iii iv
Mon-­‐
Continued Starting Finishing Friday Saturday Sunday
Thursday

Figure 3. Power demand. The numbers in the brackets represent the number of sections starting/finishing. Manufacturing (A) includes
Finishing and Yarn production, and the remaining sections of Operations finish an hour earlier before the midnight on Thursday.
Manufacturing (B) includes Dye house (DH) and Weaving (W). R and OT symbolise Retail and overtime respectively.

228  ECEEE 2014 INDUSTRIAL SUMMER STUDY – RETOOL FOR A COMPETITIVE AND SUSTAINABLE INDUSTRY
2. SUSTAINABLE PRODUCTION DESIGN & SUPPLY CHAIN INITIATIVES 2-080-14 AGHA, JENKINS

3500

3000
Consumption  (MWh)
2500

2000

1500
2011  esti.
1000
2011  man.
500

Off-­‐season On-­‐season Off-­‐season

Figure 4. Manual and estimate gas demand.

SEC  man.  gas SEC  invoiced  gas Meters

40 140,000
Consumption  per  meter  production  (kWh)

35 120,000
30
100,000

Meters  produced
25
80,000
20
60,000
15
40,000
10

5 20,000

0 0
Jan feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Figure 5. Estimate and manual SEC and monthly metres produced.

missing estimated bill in May. Such problems with estimated help to reduce and explain such patterns. The analysis based on
bills, though common, not only lead to unfair charges but higher resolution (daily meter readings) again offered a much
can seriously affect the SEC calculations as discussed above better understanding of energy consumption, and energy sav-
and shown in Figure 5 (where the total estimated energy con- ing opportunities, in the factory.
sumption for May only shows the electricity consumption).
However, when the total estimate/invoiced and actual annual
consumptions were calculated, negligible difference was no- Conclusion
ticed. The graph also showed increased demand in off-season This study demonstrates that the textile manufacturing pro-
which is due to increased heating demand in winter. This cess is complex with a number of quite specific processes con-
drives the need of investigating the efficiency of the heating tributing to overall energy patterns. By using real-time energy
system as well as improving the quality of building fabric in- data, the study attempted to estimate the energy consump-
sulation. This analysis also prompted an urgent need for ac- tion used in a case-study textile mill. The study revealed some
curate billing. technology and process efficiency improvements that might
The effect of season and rate of production activity in the be feasible. Average energy demand profiles when compared
factory on SEC is shown in Figure 5. The SEC is low during on- to working patterns showed clear occupant- and activity-sen-
season. It can be seen that higher monthly production rates im- sitive trends. Small differences in off- and on-season energy
prove the SEC, though increased heating demand in winter and demand were attributed to winter related consumption in off-
slow production rates notably increase the SEC. It also shows season. It was found that high monthly off- and on-season
that, other than the weather and season, there are more factors SEC variations were related to increased heating demand in
that could affect the SEC in such a complicated manufacturing winter.
process. Therefore, identifying these unknown factors (through Different areas of energy efficiency improvements in spe-
sensitivity analysis and observing correlation with other pa- cific technologies were also identified. Waste heat recovery,
rameters) and optimising their energy consumption through improved performance of motors, and energy efficient lighting
production management is another area that can potentially systems around the mill were found to be particularly promis-

ECEEE INDUSTRIAL SUMMER STUDY PROCEEDINGS  229

2-080-14 AGHA, JENKINS 2. SUSTAINABLE PRODUCTION DESIGN & SUPPLY CHAIN INITIATIVES

ing. The energy audit and consumption analysis revealed some buildings. DeMontfort University PhD thesis, available
actionable measures directly supporting aims of energy saving. online.
These included problems relating to a high baseline load, and Field, J., Soper, J., Jones, P., Bordass, W., Grigg, P., 1997.
investigations were made to benefit from this opportunity. The Energy performance of occupied non-domestic buildings:
use of estimated gas bills was providing misleading information Assessment by analysing end-use energy consumptions.
to the company (and their budgeting for energy), and this was Building Services Engineering Research and Technology
highlighted as another area to address. The whole exercise pro- 1997, 18: 39.
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for possible opportunities of heating/cooling related savings. boilers. Action Energy.
The study also suggested reviewing opportunities for building Good practice guide 385 (2005). Energy Efficient compressed
fabric insulation improvements. Some areas that were raised air system. The Carbon Trust.
for further investigations include, disaggregating production Good practice guide 168 (1997). Cutting your energy cost: a
and heating/cooling energy demands and the ways to reduce guide for textile and finishing industry. Department of the
it, and identifying an optimum production rate for both off- Environment, UK.
and on-season for energy efficiency. Gordić, G., Babić, M., Jovičić, N., Šušteršič, V., Končalović, D.,
Such level of energy analysis is only possible through high- and Jelic, D., 2010. Development of energy management
resolution real-time energy data and empirical observations system – Case study of Serbian car manufacturer. Energy
that were made at the factory. This highlights the significance Conversion and Management 51 (2010) 2783–2790.
of energy data analysis for organisations wishing to improve Greening, L.A., Roop, J.M., 2007. Modeling of industrial en-
energy efficiency and reduce production costs. The improved ergy consumption: An introduction and context. Energy
understanding of energy consumption that this can deliver can Economics 29 (2007) 599–608.
enable energy managers to make much better informed deci- Hasanbeigi, A., 2010. Energy-Efficiency Improvement
sions on energy efficiency in an industrial workplace. Opportunities for the Textile Industry. China Energy
Group, Energy Analysis Department Environmental
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Rapid analysis of time series data to identify This study is part of a PhD project funded by the textile company
changes in electricity consumption patterns in UK Johnstons of Elgin, in collaboration with Heriot-Watt University.

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