3. Environmental Guidelines for the Textile Dyeing and Finishing Industry
FOREWORD
For a number of years, EPA has been identifying and promoting alternatives to regulatory approaches for the
protection of the environment and the health of the community – both now and for future generations.
These methods rely largely on the ability and willingness of industry and the community to take more
responsibility for environmental performance.
Like many other industries, the textile dyeing and finishing industry has been through a period of
adjustment and accommodation to environmental requirements and regulations. The industry is now
more responsive to environmental issues and community concerns and committed to producing positive
environmental outcomes.
One of the mechanisms for achieving these outcomes and maximising environmental performance is for
industries to define and adopt Best Practice Environmental Management (BPEM) guidelines. This
publication sets out BPEM guidelines for the textile dyeing and finishing industry. The guidelines were
developed in consultation with the industry and have been endorsed by it.
These guidelines will be reviewed regularly and updated as necessary on the basis of operating
experience and the development of national standards. Users are encouraged to evaluate their usefulness
and provide comment to assist in this review process.
I commend these guidelines to the textile dyeing and finishing industry and urge their adoption and
implementation in the interests of improved environmental performance.
BRIAN ROBINSON
CHAIRMAN
Acknowledgment:
These guidelines were prepared under contract by Laney Pickett & Associates and Infotech Research.
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CONTENTS
FOREWORD....................................................................................................................................................................................................................................................................................................................................................................i
1 INTRODUCTION.................................................................................................................... 1
1.1 OBJECTIVES OF THE GUIDELINES .............................................................................. 1
1.2 SCOPE OF THE GUIDELINES ........................................................................................ 1
1.3 BEST PRACTICE ENVIRONMENTAL MANAGEMENT ............................................... 1
1.4 USING THE GUIDELINES............................................................................................... 2
2 TEXTILE DYEING AND FINISHING .................................................................................. 3
3 STATUTORY REQUIREMENTS.......................................................................................... 4
LEGISLATION ....................................................................................................................... 4
The Environment Protection Act 1970 ................................................................................. 4
Policies................................................................................................................................ 4
Some design ground level air emission concentrations [SEPP (The Air Environment),
Schedule C]......................................................................................................................... 5
Regulations ......................................................................................................................... 6
4 WASTE MINIMISATION ...................................................................................................... 7
4.1 INTRODUCTION TO WASTE MINIMISATION............................................................. 7
4.2 IMPLEMENTING WASTE MINIMISATION................................................................... 7
Potential waste minimisation outcomes................................................................................. 8
Waste minimisation ............................................................................................................. 8
5 ENVIRONMENTAL ELEMENTS ......................................................................................... 9
5.1 SITING FACILITIES AND MODIFYING EXISTING PLANT......................................... 9
Buffer distances................................................................................................................... 9
Industry............................................................................................................................... 10
Classification....................................................................................................................... 10
Recommended buffer distance (m)........................................................................................ 10
Siting .................................................................................................................................. 10
5.2 AIR QUALITY .................................................................................................................. 10
Types of emissions .............................................................................................................. 10
Common air emissions in textile dyeing and finishing ........................................................... 11
Waste minimisation ............................................................................................................. 11
Drying operations ................................................................................................................ 11
Stenters ............................................................................................................................... 11
Control systems ................................................................................................................... 12
Air emissions....................................................................................................................... 12
5.3 WATER QUALITY ........................................................................................................... 13
Policy Requirements ............................................................................................................ 14
Minimising wastewater generation ....................................................................................... 14
Liquor ratios for various dyeing processes............................................................................ 14
Dyebaths ............................................................................................................................. 15
Suggestions for bleaching .................................................................................................... 15
Treatment of dyebath wastewater ......................................................................................... 15
Salt in dyeing effluent .......................................................................................................... 16
Finishing applications .......................................................................................................... 16
Wastewater ......................................................................................................................... 16
5.4 CHEMICAL AND WASTE STORAGE AND HANDLING .............................................. 16
Chemical and waste storage and handling............................................................................. 17
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5. Environmental Guidelines for the Textile Dyeing and Finishing Industry
5.5 SOLID WASTE AND PRESCRIBED WASTE ................................................................. 19
Waste fibre.......................................................................................................................... 18
Packaging waste .................................................................................................................. 18
Packaging waste .................................................................................................................. 19
Solid waste disposal............................................................................................................. 19
Solid waste reduction........................................................................................................... 19
5.6 NOISE ............................................................................................................................... 20
Noise in textile processing equipment ................................................................................... 20
Noise................................................................................................................................... 20
5.7 ENERGY CONSUMPTION .............................................................................................. 20
Heat recovery ...................................................................................................................... 21
Lighting............................................................................................................................... 21
Compressed air.................................................................................................................... 21
Operation of stenters/drying chambers.................................................................................. 21
General................................................................................................................................ 21
Energy saving plan .............................................................................................................. 22
Energy................................................................................................................................. 22
6 ENVIRONMENTAL MANAGEMENT ................................................................................. 23
6.1 BENEFITS OF SOUND ENVIRONMENTAL MANAGEMENT ...................................... 23
6.2 KEY ELEMENTS OF AN EMS ........................................................................................ 23
Commitment........................................................................................................................ 23
Initial performance review.................................................................................................... 24
Environmental policy ........................................................................................................... 24
Suggested features of environmental policy .......................................................................... 24
Objectives, targets and the program...................................................................................... 24
Implementation and operation .............................................................................................. 25
Reviews and corrective action .............................................................................................. 25
Audits and compliance......................................................................................................... 25
ISO 14001........................................................................................................................... 25
6.3 EPA’S ACCREDITED LICENSEE SYSTEM ................................................................... 25
Environmental management ................................................................................................. 26
GLOSSARY OF TERMS ........................................................................................................... 27
APPENDIX 1 BPEM : THE NEW PARADIGM....................................................................... 29
APPENDIX 2 QUICK REFERENCE AND SELF ASSESSMENT CHECKLIST FOR
TEXTILE DYEING AND FINISHING FACILITIES.............................................................. 30
QUICK REFERENCE AND SELF ASSESSMENT CHECKLIST FOR TEXTILE
DYEING AND FINISHING FACILITIES ............................................................................... 30
APPENDIX 3 REFERENCES AND INFORMATION SOURCES .......................................... 32
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7. Environmental Guidelines for the Textile Dyeing and Finishing Industry
1 INTRODUCTION
Australia’s textile manufacturing industry improvement through the adoption of an
comprises a group of highly interrelated environmental management system (EMS).
industries. In 1992/93 the textile manufacturing 1.2 SCOPE OF THE GUIDELINES
industry in Australia employed more than
24,000 people. Victoria is the major textile- This document is intended as a guideline for
producing state, with nearly half of the industry participants seeking to adopt BPEM.
industry’s total employment. It contains information on:
Every process and almost every operation within • textile wet processing and finishing
a textile dyeing and finishing plant has an operations, and wastes generated
environmental aspect that should be considered • Government’s environmental policies and the
and for which the environmental performance regulatory environment
can potentially be improved. • opportunities for technology and process
The future development of the industry will improvement
depend on several factors, including the adoption • strategies for setting environmental goals
of Best Practice Environmental Management • achieving environmental goals via an EMS,
(BPEM). BPEM encompasses the identification waste minimisation and cleaner production
and implementation of policies that are programs.
environmentally beneficial while being
consistent with business practices and The guidelines can be used by all manufacturers
commercial practicalities. and participants in the supply chain, government
agencies and industry organisations. While the
BPEM is synonymous with Best Practice guidelines have been written specifically for
Business Management. Both aim to maximise Victoria, the principles and practices apply
the efficiency of raw material usage, while equally across Australia. The guidelines do not
minimising the consumption of energy, water disadvantage Victorian operations over those in
and auxiliary chemicals and the discharge of other States.
environmentally damaging materials.
1.3 BEST PRACTICE
BPEM is driven not by compliance, but by the
ENVIRONMENTAL MANAGEMENT
recognition that efficient resource usage results
in increased productivity as well as reduced Best Practice Environmental Management
environmental impact. (BPEM) means managing an organisation or
activity to achieve a high level of environmental
1.1 OBJECTIVES OF THE performance which is sustainable, continuously
GUIDELINES improves and is consistent with business or
economic objectives. Thus, BPEM needs to be
These guidelines will help members of the textile integrated with overall management philosophy
dyeing and finishing industry develop programs, and practice.
systems and practices to improve their
environmental performance to best practice The BPEM publication series comprises
levels, in an affordable, sustainable and efficient guidelines and codes of practice for industry
way. sectors or activities, which outline what is
needed to achieve optimum environmental
The guidelines identify the major environmental outcomes, consistent with the industry’s
aspects of the textile dyeing and finishing industry economic viability.
and describe ways industry can assess and
minimise potential and actual environmental BPEM may encompass site selection, process
impacts. Emphasis is given to the development of a design, technology choice, key operating
managed approach to continual environmental parameters and procedures, contingency
arrangements, and monitoring and auditing aspects.
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8. Environment Protection Authority
BPEM publications outline key environmental total quality management approach, to
objectives relevant to the industry or activity and voluntarily adopt BPEM guidelines and codes.
provide suggested measures to achieve these
objectives. Satisfactory implementation of the BPEM represents a commitment by management
suggested measures will result in meeting the to adopt improved practices within the company.
objectives. However, operators are able to Appendix 1 summarises the new paradigm.
consider alternative ways to meet the objectives
and to apply the best site-specific solution with 1.4 USING THE GUIDELINES
an outcome equivalent to, or better than, the These guidelines focus on key issues and areas
suggested measure. Thus, innovation is not for investigation, and identify relevant
stifled and flexibility is provided, while those information and source materials. The guidelines
seeking greater direction or certainty can simply suggest feasible improvement measures specific
apply the suggested measures. to the textile dyeing and finishing industry, as
The underlying philosophy of BPEM guidelines well as methodology and tools. The guidelines
and codes is to provide a forward looking do not aim to provide detailed technical
approach rather than simply reflect the current solutions.
norm. Where problems or issues occur within The guidelines identify the main environmental
the industry, a direction or solution to these will issues, related environmental objectives, and
be included. suggested methods by which the objectives can
A comprehensive EMS – preferably in be met.
accordance with the principles outlined in the A checklist is provided in Appendix 2 to assist
International Organisation for Standardisation plant management carry out a thorough
(ISO) 14000 series – is an integral part of evaluation of the relevant environmental issues
BPEM. These principles include the and identify all possible areas where action can
determination of all environmental aspects be taken or improvements can be made.
associated with the company’s activities, and a
process of continual improvement in
environmental performance.
BPEM provides the opportunity to harness the
following benefits:
• reduction in unit costs
• opportunities for eco-marketing
• potential reduction in EPA licence fees
• possible preferred supplier status
• potential reduction in resource consumption
• sustainable improvements in environmental
performance
• improved community perceptions and relations
• increased compliance with regulatory
requirements
• reduced exposure to risk (occupational safety
and health as well as environmental)
A BPEM guideline or code is not of itself
mandatory, but the potential exists to refer to
such a document in approvals, licences or
permits. Regulatory authorities generally expect
forward-looking manufacturers who are
committed to continuous improvement through a
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9. Environmental Guidelines for the Textile Dyeing and Finishing Industry
2 TEXTILE DYEING AND FINISHING
The textile dyeing and finishing industry has
traditionally generated large volumes of waste
and been a large consumer of energy.
As it may take 200 litres of water to produce,
dye and finish one kilogram of finished textile,
the industry has a high demand for water and
serious effluent management issues to address.
Textile finishing also requires the input of a
wide range of chemicals which, if not contained
in the final product, become waste treatment and
disposal problems.
A large proportion of the environmental issues
affecting the industry are related to the use and
discharge of water. Washings from dyeing and
rinsing operations may produce hot, alkaline,
highly saline, odorous and highly coloured effluent.
Other environmental issues requiring
consideration are energy, chemical usage,
stormwater, solid wastes, emissions to
atmosphere, contaminated land, noise,
hazardous materials, groundwater and other
environmental issues particular to the location of
a facility.
Textile dyeing and finishing
Processes employed
operations
• Pretreatment
• Wool scouring
• Dyeing
• Wool finishing
• Finishing
• Dry processing
• Bleaching
• Woven fabric finishing
• Printing
• Knit fabric finishing
• Coating
• Carpet manufacture
• Sizing and desizing
• Stock and yarn dyeing and
finishing
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3 STATUTORY REQUIREMENTS
Fundamental principles which guide Victorian Under the Act, discharges of wastes into the
Government policy and legislation on the environment must accord with State environment
environment include: protection policies (SEPPs), which identify
beneficial uses for particular segments of the
• pollution prevention (eg through waste environment, and establish ambient objectives
avoidance and risk reduction) and discharge limits.
• the precautionary principle (to enable prudent
action to be taken in the absence of complete Policies
scientific certainty) The Environment Protection Act 1970 provides
• sustainable development for the formulation and adoption of SEPPs and
• the “polluter pays” principle. Industrial Waste Management Policies (IWMPs)
by the Government.
LEGISLATION
SEPPs provide a framework for environmental
Current Acts, policies and Regulations protection in Victoria by identifying “beneficial
administered by EPA are listed in Appendix 3 uses” of the environment to be protected,
References and Information Sources. environmental objectives appropriate to those
uses, and plans and programs for the attainment
The Environment Protection Act 1970 of those objectives.
The Environment Protection Act 1970 provides IWMPs define and give effect to strategic plans for
for the control of water, air and land pollution, the management of industrial waste, including
industrial waste and the emission of noise. The waste minimisation initiatives, and the regulation of
Act is administered by EPA. waste treatment and disposal facilities.
Owners and
Environment shareholders
Protection Act
State environment TEXTILE DYEING AND
protection FINISHING PLANT:
policies (SEPPs) Employees
EPA Management response to
- Air
environmental issues in the
- Water
- Land
following areas:
- Noise Local Government
ã plant location Planning
ã waste water Regulations
ã air emissions
Industrial Waste ã solid waste
Management ã noise
Policies ã energy
Community
ã hazardous materials
ENVIRONMENT MANAGEMENT PRACTICES
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11. Environmental Guidelines for the Textile Dyeing and Finishing Industry
The State Environment Protection Policy (The Waters of Far East Gippsland (SEPP No W-
Air Environment), (the Air Policy) specifies 21).
both emission limits and acceptable ground level
concentrations for pollutants that may be emitted Some industries are undertaking direct
by industrial and other premises. application of wastewater to land for irrigation
under EPA licence conditions. This accords with
Emissions from industrial facilities must comply SEPPs for surface waters, which require that
with the Air Policy. wastewater be directed to sustainable land
disposal instead of being discharged to surface
waters, wherever this is achievable.
Some design ground level air emission
concentrations [SEPP (The Air Many wastewater discharges are to reticulated
Environment), Schedule C] sewerage systems operated by water authorities
or water businesses – in which case the
ppm mg/m3
discharge requirements are usually governed by
Ammonia 0.8000 0.60000 the operator of the sewerage system and are not
subject to direct EPA controls.
Acetic acid 0.0420 0.50000
The State Environment Protection Policy
Cotton dust (raw) 0.00670
(Control of Noise from Commerce, Industry
Hydrogen chloride 0.2000 0.20000 and Trade) No. N-1 1989, specifies permissible
noise limits in noise sensitive areas – such as
Hydrogen sulphide 0.0001 0.00014
residential buildings, hospitals and motels. The
Odour 1 odour unit acceptable noise levels which are specified are
related to the type of development in the
The Air Policy also requires the control of surrounding area. Noise limits are set by
odorous substances and particles. adjusting background noise levels for day,
evening and night conditions. If adequate buffer
Schedules in the Policy set out the control distances have been provided and maintained,
requirements for specific industries. noise requirements can more easily be met.
Schedule F-4 describes requirements to control TYPICAL NOISE LIMITS: dB(A)
discharges of waste to air from the textile dyeing
Day Evening Night
and finishing industry.
Residential 50-54 44-48 39-43
Under the Policy, EPA has discretion to exempt
operations from compliance with Schedule F in Commercial 59-63 52-57 47-52
certain circumstances. These include situations district
where compliance would preclude innovative Predominantly 63-68 57-61 52-56
control or energy saving technologies, and are industry
discussed at 5.2.
Similarly, the State Environment Protection The SEPP applies only to the Melbourne
Policy (Waters of Victoria) and other SEPPs metropolitan area. In country areas, EPA may
related to surface waters prescribe quality limits set noise targets based on the SEPP and may use
for wastewaters discharged to various receiving discretion in each particular case.
environments and water quality objectives for
those water bodies. Requirements for The Industrial Waste Management Policy (Waste
wastewaters vary for different water bodies, Minimisation) 1980 (Waste Minimisation Policy)
where different beneficial uses may apply. specifies objectives for minimising industrial waste
through avoidance and reduction, in preference to
These may be defined in SEPPs for different recycling and reclamation. Thus, this policy shifts
catchments – for example, Waters of the Yarra the emphasis from regulatory approaches and “end
River and Tributaries (SEPP No W-29) and The of pipe” pollution control to “cradle-to-grave”
controls. The Industrial Waste Strategy established
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systems and controls for hazardous wastes, as well However, sites which do not carry out both
as fostering industry agreements for waste dyeing and finishing are exempt from licensing
reduction and industry codes of practice. for discharges to air, although they still require
works approval for the installation of new plant
Among other things, the Waste Minimisation or modifications to existing plant.
Policy requires all new development subject to
works approval under the Act to develop a waste As well as being required for the installation of
management plan, with emphasis on waste new plant, works approval must precede
minimisation. alterations to existing scheduled premises, which
will increase or change waste discharges. Works
Some processes generate wastes with a high approval is also needed to relocate plant or
potential to cause environmental harm. These waste discharge points. Refer to section 19A(1)
“priority wastes” have to be specially managed of the Environment Protection Act 1970 for a
and treated to minimise the risk of pollution. All complete description of works approval
new premises and modifications to existing obligations.
processes generating “priority wastes” are
required to use best available technology. The Environment Protection (Prescribed
Waste) Regulations 1998 classify certain
Regulations industrial and domestic wastes as prescribed
The Environment Protection (Scheduled Premises waste. Prescribed waste can only be removed
and Exemptions) Regulations 1996 describe from a site by an approved waste transporter.
premises which are scheduled, and thus required to Some of the solid wastes generated by the dyeing
comply with the licensing and works approval and finishing industry are prescribed (see
provisions of the Environment Protection Act Section 5.5).
1970. Specific discharges which are exempt from The Environment Protection (Prescribed
the licensing provisions are also listed. Waste) Regulations 1998 also contain details of
Textile dyeing and finishing works are scheduled, the transport certificate system for the movement
and hence subject to works approval and licensing. of prescribed industrial waste and define the
This classification includes plants carrying out responsibilities of the waste producer, accredited
carpet manufacturing, wool scouring, and textile agent, waste transporter and waste processor.
bleaching, dyeing and finishing.
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13. Environmental Guidelines for the Textile Dyeing and Finishing Industry
4 WASTE MINIMISATION
Waste minimisation is an important part of improvements can be assessed, this data will
BPEM. By focussing on waste avoidance and allow waste reduction options to be evaluated.
reduction through use of cleaner production Pathway to cleaner production
processes and practices, pollution control and
waste disposal costs can be lowered.
Performance
Large step
PRIORITIES FOR WASTE MANAGEMENT technology
change
Small step
Reduce/Avoid incremental
improvements
Reuse/Recycle Time
Treatment
Increasing Disposal Increasing
4.2 IMPLEMENTING WASTE
benefit cost MINIMISATION
A useful approach to waste minimisation
Preference should be given to waste avoidance involves the preparation of a Waste
or reduction, ahead of recycling and reuse. If Management Plan (WMP) The starting point for
these type of actions are not possible then, and a WMP is a waste audit. This should:
only then, should treatment be considered,
• identify all gaseous, liquid and solid waste
followed by the least preferred alternative of
streams
waste disposal.
• quantify and characterise the waste streams
4.1 INTRODUCTION TO WASTE • establish the methods of waste stream
MINIMISATION generation.
Having done the waste audit, a waste assessment
Waste minimisation includes good housekeeping
is then carried out. This involves an
practices and changes to staff attitudes, as well
investigation of production processes and raw
as technical factors. Improvements as simple as
material purchases, and an assessment of all
ensuring water is turned off when equipment is
waste streams.
not working or arranging production to minimise
the amount of cleaning required may collectively A technical and economic feasibility analysis is
add up to significant gains. The potential impact then conducted to determine which waste
of such non-technological or “low-tech” minimisation opportunities identified should be
measures should not be underestimated. adopted.
Some of the smaller incremental improvements are The WMP contains an implementation timetable
easy to gain, but difficult to maintain. Teamwork and a description of the method of
and commitment from production staff, supported implementation, the anticipated cost and
by strong management and effective management environmental benefits.
systems, should enable sustainable and continuous
performance improvement. The waste minimisation program should not be a
one-off activity, but should be periodically
Another essential part of waste minimisation is reviewed to ensure that the WMP is being
understanding what wastes are being produced adhered to, and to identify any new waste
and the processes which generate them. As well minimisation opportunities.
as establishing a baseline against which
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14. Environment Protection Authority
The waste minimisation program should also be
Waste minimisation
an integral part of the company’s approach to
environmental management. Thus, it should be a
Objective
key element when an EMS is established.
To minimise waste generation and maximise
Specific waste minimisation measures are economic benefits.
described in sections 5.2, 5.3 and 5.4
Suggested measures
Potential waste minimisation outcomes • Establish a management policy in support of
waste minimisation.
• Less water inputs and wastes generated. • Establish a waste management team which
• Less chemical usage. includes operators and technical staff.
• Less energy input. • Conduct a waste audit.
• Faster dyeing cycles. • Assess viable waste minimisation projects.
• Improved economic performance. • Prepare a Waste Management Plan.
• Increase staff awareness of waste
Further information can be found in EPA minimisation principles and practices.
publications Guidelines for Preparing Waste
• Increase operator understanding of
Assessments – A Practical Guide Towards
performance factors.
Cleaner Production (Publication 277),
Guidelines for Preparation of Waste • Motivate operators to improve performance.
Management Plans (Publication 383) and Waste
Minimisation, Assessments and Opportunities
for Industry (Publication 351).
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15. Environmental Guidelines for the Textile Dyeing and Finishing Industry
5 ENVIRONMENTAL ELEMENTS
Environmental elements relating to the industry are causes such as equipment failure, accidents and
set out in the following sections. One of the main abnormal weather conditions. The buffer
potential impacts of this industry is on water distance is usually measured from the nearest
quality. Air quality, site selection, noise impacts textile activity capable of emitting odour.
and other important issues are also addressed. Buffer distances should not be regarded as an
alternative to good source control, as discussed
5.1 SITING FACILITIES AND in 5.2. Air modelling studies may be necessary
MODIFYING EXISTING PLANT at the design stage for large operations to assist
Environmental factors are one of the most in assessing the possible risk of adverse impact
important considerations in siting a new facility on local amenity.
or upgrading an existing plant. Careful site Siting should also take into account the need to
selection can reduce the risk of environmental protect sensitive natural water resources. Thus a
problems during the operational life of the plant. textile plant should not be sited within 100
Important environmental factors to be metres of surface waters, nor be located on a
considered in siting textile plants are: flood plain or in declared special water supply
• proximity to residential areas (buffer distance catchment areas, unless adequate protection of
requirements) surface and groundwaters can be demonstrated
• future land use by the proponent.
• site hydrology Buffer distances between textile plant processing
• weather and prevailing wind conditions in operations and sensitive areas should be
relation to sensitive land uses determined with reference to Recommended
• geology and ground permeability Buffer Distances for Residual Air Emissions
(EPA Publication AQ 2/86).
• site contamination
• proposed nature of wastes and treatment Where a new or modified facility is proposed
systems within a recommended buffer, a risk assessment
• water supply and availability of waste-water should be carried out to assess the potential for
treatment and disposal facilities adverse effects on sensitive uses. If a risk
assessment shows unacceptable risks, alternative
• presence of incompatible industrial neighbours.
siting or technology need to be considered.
These issues should be considered at greenfield
sites and when relocating or modifying existing Buffer distances usually are considered for new
plant. or green field sites or for additional work on
existing sites. If there is to be substantial
Requirements for planning new industrial development on existing sites with potentially
developments are prescribed under the Planning inadequate buffers, the site developers usually
and Environment Act 1987. Planning approval need to show that the introduced technology will
may be required for the establishment of a textile reduce any risk of adverse impacts.
plant.
A buffer may be occupied by compatible non-
Buffer distances sensitive land uses. Buffer zones can also be
provided within a site by wise use of available
In order to provide a basic level of protection land. Some typical buffer distances for textile
from odour, dust and noise, a textile dyeing and industries taken from Recommended Buffer
finishing plant should not be located Distances for Residual Air Emissions (EPA
inappropriately with regard to designated Publication AQ 2/86) are provided below.
residential areas or other sensitive land uses.
This is to protect the amenity of the area by
anticipating possible unintended or accidental
emissions that may occasionally arise from
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16. Environment Protection Authority
Industry Classification Recommended buffer
distance (m)
Dyeing or finishing of cotton, linen 300
and woollen yarns and textiles
Carpet backing with latex 300
Production of artificial fibres and (a) cellulose nitrate or viscose fibre 1,000
textiles
(b) other synthetic fibres and 500
textile
Treatment or production of textiles (a) using carbon disulphide 500
(b) using other substances Determined by EPA on
site-specific basis
Rope, cordage and twine 100
Wool scouring 200
Siting 5.2 AIR QUALITY
Types of emissions
Objective
To minimise environmental impacts by The main emissions to atmosphere from textile
appropriate site selection. dyeing and finishing processes are odours and
particles. These emissions arise from drying,
Suggested measures bleaching, heat setting, stentering and other
• Site new plants in accordance with buffer finishing processes. Their control represents a
distance recommendations Recommended major challenge to the industry.
Buffer Distances for Residual Air Emissions
The SEPP (The Air Environment) contains
(EPA Publication AQ 2/86).
specific requirements for stationary sources and
• Site at least 100 metres from surface waters. specifies emission limits for various pollutants.
• Site so that prevailing winds will not
transport pollutants and noise towards As previously noted, Schedule F4 of the State
sensitive land uses. Environment Protection Policy (The Air
• Consider the current and future proximity of
Environment) sets out emission controls for
sensitive developments. textile dyeing and finishing plants.
However, the Policy allows EPA to exempt sites
from compliance with Schedule F, subject to
ambient objectives being met. The policy identifies
the following matters as being relevant:
• compliance with policy would increase or
create waste disposal problems
• compliance would preclude the use of energy
saving technology or innovative controls
• compliance cannot be achieved by using
reasonably available technology
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17. Environmental Guidelines for the Textile Dyeing and Finishing Industry
• maximum ground level concentrations will be preceded by screening for their potential to
not be exceeded and the discharge will not generate odour and smoke emissions
adversely affect any beneficial use of the
environment. Waste minimisation
In considering an exemption, EPA will look at Waste minimisation is an integral part of
how effectively the proposed alternative BPEM. Each facility should initially investigate
technology will control emissions compared with opportunities for waste reduction through
the controls set out in Schedule F4. process, material or product changes which may
result in elimination of emissions or reductions
In accordance with the SEPP, EPA licences in their quantities or toxicity.
impose specific requirements for emission
controls for a production facility. Emissions can For example, emissions will be minimised for a
often be estimated from a knowledge of products particular heat setting or stentering process if the
used and volatiles likely to be emitted, but coating used on the fibre is applied at the
usually need to be determined by testing. Ground optimal level. Non-optimal coating layers will
level concentrations can then be determined at result in correspondingly greater emissions and
the peak operating conditions through the use of the facility will lose money in wasted inputs as
plume dispersion modelling. well as the increased requirement to treat wastes.
In recent years, the use of toxic moth proofing
Common air emissions in agents that do not biodegrade readily – such as
textile dyeing and finishing pentachlorophenol – by the textile finishing
industry has ceased. Alternatives to
Emission Sources formaldehyde based resins are also available to
Water and steam Drying, stentering and reduce the environmental risk of this biocide.
heating operations Quantification of the processes which generate
Carbon Dioxide Boilers, forklifts, engines emissions will lead to better understanding of
and transport waste generation and hopefully the identification
of both simple and more complex opportunities
Oils and mists Finishing, stentering, to reduce emissions.
proofing
Drying operations
Solvents, VOCs Stentering, drycleaning and
washing processes There are several different technologies
available to textile finishing facilities for drying.
Ammonia Dyeing and printing Each of the drying processes – mechanical
Formaldehyde Coating, crosslink finishing drying, steam heating, hot air, or RF drying
systems – should be examined from the point of
Carriers Dyeing environmental outcomes as well as efficiencies,
energy consumption and cost. Monitoring
Organic finishes Coating and finishing intermediate and final product moisture levels
and using this information to optimise drying
BPEM involves investigation of these emissions, processes is sound practice.
identification of ways to avoid or minimise them,
and formulation of controls on residual Stenters
emissions to reduce any negative impacts on the
environment. This process should consider Stenters may be major emission sources of
emissions during both normal and abnormal particle emissions. As well as applying waste
operating conditions – such as plant and process minimisation practices – such as using optimum
start-up, commissioning of new plant, power and coating levels and applying less volatile coatings
equipment failure, and fires. – the following steps should be considered:
The introduction of new products such as dye
carriers and lubricating and finishing oils should
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18. Environment Protection Authority
• examining opportunities to use less volatile gases from an afterburner could be used to preheat
finishes, less toxic and odorous chemicals in incoming waste stenter gases.
dyeing
• turning off power to machine when not in use
(this may be automated)
• optimising oven performance (measure it first)
• splitting the oven exhaust wastes and
recycling the clean streams (most of the
volatiles are emitted in the first oven)
• warming up incoming gases using heat
exchange with out-going hot emissions
(equipment has been specifically designed for
this application)
• using moisture meters to minimise the
amount of exhaust gases required for the
process by motor control
• using a mist eliminator to reduce particle emissions.
Control systems
Emissions of waste gases can be controlled
using stack gas treatment systems.
The following emission control systems should
be investigated as part of BPEM:
• diversion of stack emissions to neutralise
alkaline effluent (CO2 to CO3_H2CO3)
• diversion of stack emissions through the
boiler, to reduce VOC and odour emissions
• cooling and filtration (heat recovery possible)
• gas scrubbing (water pollution and operating
cost high)
• electrostatic filtering (removal of particles
requires energy).
The applicability of the above approaches will
depend on individual circumstances.
Some of these systems are very efficient in
contaminant removal, but do not necessarily
eliminate wastes. For example, stack gas
scrubbing to remove volatile organic
components does not destroy these
contaminants, but condenses them into a liquid.
This has to be discharged as effluent or as a
sludge requiring specialised disposal. This
reinforces the desirability of waste minimisation.
It is possible to save energy by using hot emissions
to heat up incoming gases. For instance, exhaust
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19. Environmental Guidelines for the Textile Dyeing and Finishing Industry
5.3 WATER QUALITY
Air emissions
The most difficult environmental issue for the
Objective textile dyeing and finishing industry is the
To reduce air emissions and conserve energy generation of wastewaters. Effluent quality
resources, to ensure there is no health risk or limits can be difficult for companies to meet
loss of amenity. amd are likely to become more stringent,
requiring textile dyeing and finishing operations
Suggested measures to employ waste minimisation, to avoid resorting
• Review and analyse emissions and monitor to expensive on-site treatment.
and analyse consumption of inputs which
generate these emissions. Environmental issues associated with textile
industry effluents include:
• Assess opportunities to replace volatile with
non-volatile components and toxic with lower • residual dyestuffs – toxicity, colour,
toxicity components. biodegradability
• Assess each material for its toxicity and • halogenated organic compounds (AOXs)
environmental hazards:
• heavy metal contamination (Cr, Cu, Zn)
— is it a priority waste, listed in
Schedule A of the Waste Minimisation • surfactants and synergistic relationship with
Policy? toxicants
— does it contain toxic components? • salts in effluent which is to be reused for land
— is it reactive with other materials? application
— will it photodecompose? • auxiliary agents for dyeing – toxicity and
— is it particularly odorous? biodegradability
• Review all coating materials for volatility • finishes – toxicity and biodegradability
and odour potential.
• elevated temperatures
• Reduce coating concentrations where practical.
• Run fans and ventilation equipment more • high levels of total oxidised sulphur (TOS)
efficiently: • high BOD levels.
— use speed variation to reduce emissions Policy requirements
— switch off equipment when processes are The first priority for wastewater management is the
not running. implementation of waste avoidance and reduction.
• Reuse exhaust gases in other parts of the
plant or off-site. Where reticulated sewer is available, wastewater
should be directed to the sewer, with the
• Automate the operation of machinery to
approval of the system’s operator. Pretreatment
switch off when not in use.
may be required.
• Monitor and control fugitive emissions.
• Capture emissions from heat setting Where sewer is unavailable, the preferred
machines and duct to a chimney. method of managing wastewater is to use it for
land irrigation, in accordance with the SEPP
• Use pressure dyeing machines where
(Waters of Victoria). Irrigation schemes should
practical.
be designed in accordance with Guidelines for
• No heat setting of goods with excess volatiles Wastewater Irrigation (EPA Publication 168),
(more than 0.3% w/w). to be sustainable and avoid contaminating land
• Ensure atmospheric batch dyeing machines or groundwater.
are vented and fugitive emissions controlled.
Disposal to surface waters should only be
• During dye carrier and/or sulphur operations considered if a combination of waste
for atmospheric batch dyeing, machines minimisation, recycling and land irrigation
should be completely enclosed with any cannot avoid a wastewater discharge to surface
venting ducted to a chimney. water.
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If discharge to surface waters is being • optimise production to reduce liquor ratios
considered, the requirements of the relevant
SEPPs must be observed. Key parameters for • optimise and reduce the number of rinses
policy compliance include toxicity, colour and • optimise cycle times and job turn-around
total dissolved solids (TDS). Discharges should
• use lower liquor ratio machinery
not display acute or chronic toxicity; discharges
should not cause objectionable colours in • reduce reprocessing through better quality
receiving waters; and TDS levels in receiving controls
waters should not be increased unacceptably. • combine rinses with scours
To ensure policy compliance, wastewater quality • scours may be done in dyebath
should be comparable with that of the receiving
• recycle steam condensate back to boilers
waters. This would be likely to require a
treatment regime combining processes such as • recycle cooling waste to use as hot/ mixed
sedimentation, chemical dosing, dissolved air hot-cold fill
flotation, biological oxidation and filtration. The • recycle rinses as feeds for dyebaths and scour
capital and operating costs of such complex baths
treatment processes may be significant. These
processes also generate sludge, which requires • recycle “clean rinses”.
an environmentally sound disposal route. A key factor in water usage in dyeing, scouring,
bleaching and other textile finishing processes is
An assessment of potential TDS impacts would
the “liquor ratio” – the volume of liquor required
have to consider the characteristic high TDS
in the process per kilogram of fibre. Dyeing
levels of textile industry wastewater and the
plants have been developed which operates with
large natural TDS variation in Victorian waters
progressively lower liquor ratios to reduce water
(from tens of mg/L to thousands of mg/L). Thus,
usage. Care should be taken to investigate the
such an assessment should be site-specific and
overall environmental impact of some of these
may have to consider treatment processes such
processes before a decision is made to adopt
as reverse osmosis.
them.
Minimising wastewater generation
Liquor ratios for various dyeing processes
As for emissions to atmosphere, the general
approach to wastewater minimisation is to:
Process litres/kg
• audit all wastewater streams Dyeing winches 20-30 : 1
• assess options for minimising each individual
Hank machines 30 : 1
stream
• prepare a plan for implementing the selected Jet dyeing 7-10 : 1
options. Package dyeing 5-8 : 1
A good starting point is to ensure that
Pad batch 5:1
formulations do not use excessive amounts of
chemicals or water. This may involve a program ULLR dyeing 5:1
of trials and monitoring. Once the optimum
formulations have been determined, operating Exhaust dyeing can achieve high levels of dye
procedures should be put in place to ensure they fixation to the fibre and may produce
are adhered to. A number of Victorian plants significantly lower levels of dye waste.
have successfully used this approach.
Simple effluent volume reduction may result in
When assessing options to minimise wastewater reduced effluent disposal charges, but the effect
streams, consider the following methods: of volume reduction may simply be to
concentrate contaminants. This could require
• minimise machine cleaning through better contaminant minimisation or treatment to meet
maintenance and production planning
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21. Environmental Guidelines for the Textile Dyeing and Finishing Industry
trade waste acceptance standards or to reduce water in fixing and washing off (soaping and
environmental impacts in cases of discharges to rinsing)
surface waters. • improving repeatability of shades – hence
reducing the need to correct shades – by
Dyebaths
maintaining more accurate records and better
Dyebaths generally have high levels of dye delivery systems.
BOD/COD, colour, toxicity, surfactants, fibres
and turbidity, and may contain heavy metals. Suggestions for bleaching
They generally constitute a small fraction of
total liquid effluent volumes, but may contribute • Avoid chlorinated bleaches where possible
a high proportion of total contaminants. (hydrogen peroxide may be used to avoid
pollution).
Dyes naturally tend to generate highly visible
colour problems. The reduction of colour in the • Recycle unspent bleaching liquors.
spent dyebaths will help reduce the final effluent • Avoid the need for bleaching by minimising
colour. reprocessing.
Methods to reduce dyebath contamination levels • Reduce machine cleaning requirements with
include: more timely maintenance and by planning
• choose biodegradable surfactants production to follow light shades with dark.
• reduce salt usage in dyebaths – high levels of • Post-bleaching of peroxide stable shades
salts make reuse of the spent liquors difficult bleach in boil-off bath of dyeing.
and expensive
• ensure dye fixing is maximised Treatment of dyebath wastewater
• recycle light shade dyebaths into darker shades Technologies are available to purify almost any
• flocculate or otherwise remove dyes from waste stream from a textile facility. However,
dyebaths before dropping them to effluent, or the cost of many of the treatment options makes
for recycling. waste reduction an attractive alternative.
Both dyes and application technologies are being The following techniques may be used
continually improved. Each facility should individually or in combination:
balance the cost of dyes and processes against
the environmental cost of cheap materials and • electrolysis
wasteful processes. In particular, plant • adsorption (should be reversible)
management should examine:
• ultra-filtration, and reverse osmosis
• use of low salt dyes • activated sludge digestion
• dye toxicity and carcinogenicity, and heavy • dissolved air flotation
metal content
• bacterial treatment (aerobic and anaerobic)
• pad batch, spray and other low volume
application techniques • ozone treatment
• use of CO2 for neutralisation instead of • oxidation/reduction (may lead to more
mineral acids pollution)
• use of low temperature dyeing techniques • flocculation – alum and ferric (again may
lead to more pollution).
• use of dyes with high levels of exhaustion
The removal of dyes and other contaminants
• use of dyes that fix well onto the fibre and
may simply transfer the waste problem from one
require less rinsing
phase to another. Many of these treatments will
• replacement of reactive dyes with direct dyes end up with a toxic byproduct that may have to
– especially with heavier shades – to save be disposed of at a secure landfill.
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The BPEM solution to the problem of residual Once options for material substitution have been
dyes and auxiliaries in effluent is to maximise examined, the next step to reduce contamination
the fixation of the dyes on the fibre and to of the effluent from finishing materials is to
consider recycling the spent dyebath, after monitor and improve the level of fixation to the
treatment if necessary. fibre. If padding or spraying is used as an
application method, can the over spray and
Salt in dyeing effluent remaining baths be kept and reused? If these
Salts are an important issue for the textile options are exhausted it may be possible to
dyeing industry. Common salts are required in a separate and treat these waste streams before
number of dyeing systems – particularly for they are discharged.
cotton dyeing where reactive dyes are used.
Wastewater
The low value of salts makes them a poor target for
recovery and the small nature of the ions
Objective
comprising salts makes them difficult to remove by
standard effluent treatment methods. They are not To reduce water consumption and wastewater
removed by biological treatments and require loads.
physical or chemical separation techniques (reverse
Suggested Measures
osmosis, evaporation, electrolysis).
• Audit the wastewater streams to determine the
Salts may affect the application of effluent to processes causing high volumes of water use
land for irrigation purposes. It may be possible and those generating contaminated effluent.
to examine the use of different salts, which
improve effluent sodium adsorption ratio (SAR)
• Optimise formulations, to reduce chemical
and water usage.
and hence improve reuse options.
• Examine opportunities to replace toxic and
BPEM is to use low salt dyeing techniques and non-biodegradable chemicals and dyes with
to examine opportunities for dyebath recycling. alternatives that have a low toxicity and are
readily biodegradable.
Finishing applications
• Consider processes that use less water and
Finishing can lead to high levels of pollutants in chemicals.
wastes. The moth proofing agents most commonly
used – pyrethrins – have a high degree of insect • Improve quality procedures to reduce
toxicity. If this material is over applied, does not reprocessing.
adhere well to the fibre, or washes off in post- • Use preventative maintenance to reduce
treatments, the resulting wastes can be highly breakdowns and associated wastes.
contaminated with pyrethrins.
• Confirm reduction targets and associated
Heavy metals in finishing treatments and other savings.
contaminants such as fluorides used for flame- • Identify possible reduction opportunities
proofing can also lead to contamination of throughout processes.
wastewater that is difficult to treat.
• Examine automated control technologies
Finishing treatments should also be examined in
terms of the end use of the products. The
• Establish reduction and recycling strategies
for high volume waste processes and
“cradle-to-grave” approach to environmental
contaminated waste streams.
management will include consideration of the
recyclability or reusability of the textiles after
the products have finished their natural life. If a
product is likely to be incinerated there may be
environmental problems if it contains heavy
metals or resins that may break down to form
toxic gases.
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23. Environmental Guidelines for the Textile Dyeing and Finishing Industry
5.4 CHEMICAL AND WASTE — isolating and recovering spilled
STORAGE AND HANDLING materials before they enter the
environment or sewerage systems
Although it is necessary to store chemicals and
— containing and cleaning up spills which
wastes at textile industry sites, this inevitably
have entered waterways
creates an environmental risk. Spills can
severely pollute land, surface waters and — disposal or reuse of recovered residues
groundwater. A spill of even a low toxicity, — contacting key company and
biodegradable material to a waterway can lead government agency personnel to advise
to severe oxygen depletion and the death of them of the emergency.
aquatic life. Although spillage may be • Provide continuous staff training.
accidental, the responsible organisation may be
liable for any environmental damage which
Chemical and waste storage and handling
occurs.
Staff training is particularly important, as many Objective
spills are the result of human error. Management To reduce the risk of spillage or other losses
must ensure that staff are trained and prepared which cause environmental damage.
to prevent spills and know how to take
corrective action to contain split material or Suggested measures
prevent its release into the environment. This • Audit chemical and waste storage and
type of training must be continuous. handling, and evaluate the associated
environmental risks.
Staff must have access to adequate information
about the nature of materials used in the work • Determine protective strategies and prioritise
place, the hazards associated with their use and these in a plan, which may include the
safe handling and spill control measures. A following:
comprehensive and up to date set of material — reducing inventories and using less
safety data sheets must be available, along with hazardous materials
emergency procedure guides and safe handling — storing liquids in above ground storage tanks
notices in storage areas. — using automatic dispensing systems
Clearly, a program to reduce the environmental — installing bunding in accordance with
risks associated with spills should be carried Bunding Guidelines (EPA Publication
out. It should include the following elements. 347) and Australian Standard AS1940
• Firstly, audit current chemical and waste
— installing spillage
containment systems.
and fire water
storage facilities, and identify potential risks.
• Implement a program to reduce risks, based
• Establish an inspection, maintenance and
monitoring program.
on the results of the audit. The program
should consider: • Establish a staff awareness and training
— reducing inventories program.
— replacing below ground with above • Develop, and keep up to date, emergency
ground tanks plans and manifests.
— replacing hazardous materials with less • Confirm that the storage and handling of
hazardous/non-hazardous materials (for chemicals complies with the Dangerous
example, replace mineral acids with Goods Act 1985 and applicable Dangerous
acetic or formic acid) Goods Regulations.
— using automatic dispensing systems
— bunding.
• Provide contingency plans to deal with any
spills which occur. Plans should consider
issues such as:
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5.5 SOLID WASTE AND PRESCRIBED
WASTE
Solid wastes do not generally present major
environmental problems in textile dyeing and
finishing. Most of the solid waste is generated
by salt bags, dyestuff and chemical containers
and packaging. Other solid waste includes waste
fibre and sludges from water purification and
effluent treatment facilities.
Waste fibre
Waste fibre can be recycled as a feedstock for
other operations, including:
• cleaning
• dye adsorption
• boiler feed
• external uses
• quilting
• fibre pilling
• insulation
• geotextiles
• low grade products
• respinning and weaving
• non-wovens.
Packaging waste
Chemical containers present a disposal problem,
even when empty. A number of regulations
apply to reuse and transport of empty chemical
containers. Production facilities should
investigate bulk chemical delivery rather than
supply in small containers to avoid disposal
problems.
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25. Environmental Guidelines for the Textile Dyeing and Finishing Industry
Packaging waste Solid waste reduction
Objective Objective
To reduce all forms of packaging going to To minimise the production of all forms of solid
landfill. waste.
Suggested measures Suggested measures
• Accept goods in bulk wherever practical. • Audit solid wastes generation and evaluate
• Use returnable containment systems disposal systems and costs.
(collapsible minibulk containers). • Identify opportunities to avoid or reduce solid
• Use recyclable containers. wastes:
— reduce packaging waste
• Seek to return all non-recyclable containers
— seek to have suppliers accept returns of
to suppliers.
left over materials
• Segregate containers into recycling areas — seek greater process efficiencies and less
(plastics, paper and cardboard, steel). reprocessing
• Reuse non-hazardous containers. — introduce processes that generate less solid
wastes.
Solid waste disposal • Examine opportunities to reuse solid wastes
Solid wastes from a dyehouse and finishing currently going to landfill, for example:
plant have traditionally gone directly to — composting of putrescible solid wastes
municipal tips. Under the Environment — food wastes as animal feeds
Protection Act 1970 the waste generator has a — recycling fibre wastes
responsibility to ensure that wastes are properly
disposed of. Some solid wastes generated by the
• Establish quantification and monitoring
systems for prescribed wastes.
textile finishing and dyeing industry are
classified as prescribed wastes and must be • Wherever practical, minimise generation of
transported in accordance with the Environment prescribed wastes.
Protection (Prescribed Waste) Regulations • Establish systems to ensure that prescribed
1998 to a suitably licensed landfill. wastes are managed in accordance with the
These include: relevant Regulations.
• boiler blowdown sludge
• filter cake sludges and residues
• dyes
• chromium compounds
• oxidising and reducing agents
• peroxides
• surfactants
• pesticides.
For a complete listing, refer to the Environment
Protection (Prescribed Waste) Regulations 1998.
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5.6 NOISE
Noise
Noise coming from a textile production plant
may have a significant impact on the local Objective
environment. Textile plants in the Melbourne To ensure no noise nuisance results from the
metropolitan area must comply with the State facility.
Environment Protection Policy (Control of
Noise from Commerce, Industry and Trade) Suggested measures
No. N-1. • Locate unloading and transport operations
Impacts are greater where, as is the case for away from residential and other noise
many sites, textile plants are close to residential sensitive areas.
areas. Because of the high potential for noise to • Ensure “hooters” are used for emergencies
affect amenity, management should give high only.
priority to liaising with the local community so • Avoid use of paging systems.
that it can be aware of, and effectively resolve,
noise issues. Potential noise impacts should be • Eliminate water hammer.
considered at greenfield sites and when existing • Maintain steam and air hoses.
plant is being modified or relocated.
• Isolate equipment with vibration absorbent
Noise abatement can often be achieved by pads.
simple non-technical measures such as closing • Consider using acoustic louvres and double
doors and shutter windows, controlling delivery glazing to reduce noise.
hours and restricting fork lift movement on open
roads. Telephones and loudspeakers can affect • Liaise with the local community to identify
residential areas and should be considered. noise issues.
Simple measures such as ensuring loudspeakers
are directed away from residential areas may be
effective.
Where noise abatement requires more detailed
analysis and control, an acoustic consultant
should be used.
Noise in textile processing equipment
Source typical levels
dB(A)
Steam injection systems
Ventilation fans 55-69
Hooter/siren 57-70
Air compressors 46-69
Brushing machines
Hydro extractors
Forklift 50-60
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27. Environmental Guidelines for the Textile Dyeing and Finishing Industry
5.7 ENERGY CONSUMPTION • Use of daylight compensation dimmers.
Energy efficiency and waste minimisation are Compressed air
often closely linked. Measures that avoid or
reduce wastes often save energy and vice versa. • Reduce operating pressure where possible.
Many of the energy savings that may be made in • Eliminate all leaks – even small leaks can be
any facility relate to staff awareness of the need costly.
to conserve energy and their attention to small • Shut down compressors on main air lines
measures that can collectively make a big during idle periods.
difference. Heating and lighting energy • Size the compressors to the application.
requirements can be reduced through sensible • Size main lines correctly.
conservation measures.
Operation of stenters/drying chambers
Textile dyeing and finishing facilities use
significant quantities of energy for steam, power • Do not over dry (temperature and time).
for motors, direct heat for drying, air • Use heat exchangers between inlet and outlet
compressors, air conditioning and cooling. Each air.
facility should consider and quantify the energy • Aim for a maximum exhaust moisture of 150
usage of its processes and its overall energy g/kg when drying (less air = less energy).
costs. The main opportunities for energy savings • Use auto pilots.
will reside in the largest energy-using processes
• Investigate low pick-up techniques and
and products. Derivation of energy consumption
technologies.
benchmarks (for example, kJ/kg of production)
is a good starting point if the various production • Minimise energy use during stand-by periods.
processes can be so characterised.
General
Comparisons of the energy costs of drying • Examine and use low temperature technologies.
methods usually present good opportunities for
energy and cost savings. Steam, gas and RF • Exchange heat from hot effluent to incoming
drying comparisons have shown that it is waters for boilers or hot baths.
important to look at the efficiency of heat • Recover heat from boiler stacks and hot
production and then the efficiency with which waste streams.
this heat is transferred to the fibre.
• Install frequency inverters on electric motors
Options to reduce energy consumption which to reduce electricity usage.
should be considered are outlined below. • Provide cut off systems to save energy during
start up and shut down, and stagger
Heat recovery equipment start ups.
• Recover cooling water and use it as heated
input water.
• Insulate dyeing vessels, dryers and boilers.
• Return steam condensate to boilers. • Insulate dryers.
• Reuse different process waters. • Use more efficient pumping systems
• Examine the efficiencies of existing heat (displacement pumps rather than pressure
exchangers. pumps).
• Recycle cooling waters as heated input
Lighting waters for rinses or dyebaths.
• Look for opportunities to delamp by better • Upgrade to high efficiency pumps and
use of natural light, upgrading lamp electric motors.
efficiencies, or adjusting areas which are
overly bright. • Match the pump size to the application.
• Use of motion sensor switches (smart • Measure boiler output in kilojoules and
lighting). calculate the energy yield.
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• Review dyeing programs and reduce Energy
temperatures and time settings where possible.
• Use of combustible wastes as fuel. Objective
• Consider regulating air or water flows in air To improve the efficiency of energy usage and
conditioning with variable speed drives or reduce consumption of energy per unit of
motors. production on a continuous improvement basis.
Energy saving plan Suggested measures
The saving of energy requires a monitoring • Conduct an energy audit to determine the
program, the setting of goals and targets, and major areas of energy use, and define and
concrete plans to implement changes. A review value each waste energy stream.
of program outcomes and the accounting of • Determine and monitor the efficiency of
energy consumption to individual processes and major energy using processes.
products is important for making decisions on • Examine opportunities for energy use reduction.
the energy and environmental costs of products
and processes. • Compare systems for efficiency in terms of
cost and actual energy use.
Any reduction in energy usage has the additional
benefit of reducing greenhouse gas emissions, as
• Prepare a program of improvements in
efficiencies.
well as reducing operating costs.
• Recognise and reward contributions from staff.
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29. Environmental Guidelines for the Textile Dyeing and Finishing Industry
6 ENVIRONMENTAL MANAGEMENT
EPA encourages the responsible self- solved promptly and efficiently. However, it
management of environmental issues by provides a framework within which the
industry through environmental management organisation’s skills and resources can be used
plans and environmental management systems effectively in tackling the opportunities for
(EMSs). EPA’s ability to recognise good environmental improvement, starting with the
environmental management has been enhanced highest priority projects – those that involve
through the introduction of the accredited compliance and issues of due diligence for
licensee system. These initiatives should be management and those that can make a
incorporated in the BPEM program. significant positive impact on environment and
economic performance.
6.1 BENEFITS OF SOUND The EMS should not exist as an independent
ENVIRONMENTAL element in a management program. It should be
MANAGEMENT integrated with other management structures –
With commitment from management and staff, such as those for production, planning, quality
a company can gain continuing advances in management, and occupational health and
environmental performance through the safety. An integrated approach will yield the
implementation of an EMS. maximum benefits because the fundamental
elements of these management systems are
Establishment of an EMS within a company related and incorporate commitment, policy,
enables the integration of environmental targets and programs, monitoring, and review
policies and programs into management policy to achieve continuous improvement.
and business operations. The EMS includes:
In summary, the benefits of sound
• the adoption of environmental policies and environmental management include:
objectives
• the formulation of environmental plans and • improved performance (environmental and
programs economic) and reduced risk
• the setting of performance targets • due diligence (regulatory, compliance and
• the establishment of a system of regular more)
monitoring and review of environmental • enhanced community relations and perceptions
performance.
• potential for eco-marketing
A key feature is that it involves personnel at all • sustainable operations (that do not create
levels of the organisation in the achievement of resource or waste problems)
environmental objectives.
• performance measurement for better
An EMS is a highly desirable component of the production management
total management program for a textile dyeing
and finishing operation. Environmental
• improved corporate image.
management needs to be pro-active and deal
6.2 KEY ELEMENTS OF AN EMS
with the full range of environmental issues –
both routine and unexpected. Reducing Commitment
wastewater loads needs as much attention as
controlling chemical spills. Management needs to be fully committed to
environmental improvement to provide the
Environmental management is an ongoing sustained impetus to introduce and implement
process, not a one-off exercise or a single an EMS, and to win the commitment and
management plan. A fundamental principle of support of staff at all levels in the organisation.
EMS is continuous improvement. The person or people with principal
An EMS itself does not guarantee that all of a responsibility for EMS implementation must be
company’s environmental problems will be
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