Cleaner Production - it is the major advancement in the chemical industry or in all sectors. I have provided this file its all about TEXTILE INDUSTRIES with CP. So go through it.

1. Application of Cleaner production in
Small-scale sector
Introduction:
Cleaner production has gained acclaim for its proven ability to reduce industry’s environmental
burden while simultaneously improving industry’s bottom line. Production practices and
technologies for small to medium sized enterprises developed and disseminated rapidly in
particular in Europe, North America, and more recently as well in Australia, New Zealand and
South and East Asia.
The national strategies and policies will be adopted cleaner production fostering strategies and
policies will be implemented and progress reported annually. The report seeks to contribute to
the application of cleaner production in small to medium sized enterprises in India. In Indian
scenario as well that growth in the rate of material extraction and waste generation is owing to
limitations of process efficiencies that happen to be particularly magnified in small scale
industries owing to their traditional technology countries in adequately transforming inputs into
final products. Thus, pollution (as undesirable contamination and consequent hazard etc. is
viewed consequence of all kinds of industrial activities – low tech or hi tech.

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Cleaner Production Concept and Practice:
Cleaner production refers to the continuous application of an integrated preventive
environmental strategy to processes, products and services to increase eco – efficiency and
reduce risks to humans and the environment. Its aims in particular at:
Production processes: Conserving raw materials and energy, eliminate toxic materials, and
reducing the quantity and toxicity of all emissions and waste before they leave the process;
Products: reducing the environmental impact along the life cycle of a product, from raw
materials extraction to its ultimate disposal;
Services: incorporating environmental concerns into designing and delivering services.
Cleaner production requires changing attitudes, responsive environmental management and
evaluating technology options.
Cleaner production aims at making more efficient use of natural resources (raw material,
energy, and water) and reducing the generation pf wastes and emissions at the source. A
division in five prevention practices is most common (e.g., USEPA, 1998;1992; UNEP, 1994)
Product modifications change the product characteristics, such as shape and material
composition. The lifetime of the new product is, for instance, expanded, the product is easier
to repair or the manufacturing of the product is less polluting. Changes in product packaging
are generally also regarded as product modification.
Input substitution refers to the use of less polluting raw and adjunct materials and the use of
process auxiliaries (such as lubricants and coolants) with a longer lifetime.
Technology modifications include for instance improved process automation, process
optimisation equipment redesign and process substitution.
Good housekeeping refers to changes in operational procedures and management in order to
eliminate waste and emission generation. Examples are spill prevention, improved instruction
of workers and train.
Onsite recycling to the useful application of wate materials or pollutants at the company where
these have been generated. This could take place through reuse as raw material, recovery of
material or useful application.
Benefits of cleaner production:
Cleaner production can reduce operating costs, improve profitability and worker safety, and
reduce the environment impact of the business. Companies are frequently surprised at the cost
reductions achievable through the adoption of cleaner production techniques. Frequently,
minimal or no capital expenditure is required to achieve worthwhile gains, with fast payback
periods. Waste handling and charges, raw material usage and insurance premiums can often be
cut, along with potential risks.

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 Reduce waste disposal cost.
 Reduce raw material cost.
 Reduce Health and safety Environment (HSE) damage cost.
 Improve public relations/ image.
 Improve companies’ performance.
 Improve the local and international market competitiveness.
 Help comply with environmental protection regulations.
On a border scale, cleaner production can help alleviate the serious and increasing problems of
air and water pollution, ozone depletion, global warming, landscape degradation, solid and
liquid wastes, resources depletion, acidification, of the natural and build environment, visual
pollution and reduced bio-diversity.
Recommendations:
The ministry of environment (MOE) is presently the principal regulatory body that looks after
environment issues. The regulatory process is operated through various instruments such as
Environment Impact Assignment (EIA) and ambient emission / effluent standards. The
enforcement of these instruments and various provisions at MOE is unfortunately weak. The
MOE does not have a strong enforcement division that is ably supported by a network of field
monitoring laboratories and equipment.
External incentives – an appropriate govt. policy and regulatory formula must be place to
provide effective incentives for the firms to adopt cleaner production.
Response of the firms: In many cases, firms are incapable of responding to the incentives and
in such cases, it may be appropriate to assist the firms to adjust. The approaches adopted for
this purpose will vary considerably depending on the characteristics of the sector and of the
firms involved.
CLEANER
PRODUCTION
Input
Substituion
Technology
Modification
Good
Housekeepi
ng
Product
Modification
On site
Recycling

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Problems of University, Industry and Government in the promotion of
Cleaner Production (CP)
Industry Government University/ Research
Institutions
Lack of “waste
management culture,”
Leading to the mix of wastes
at the source
Lack of clear and continuous
policies to support CP.
Slowly updated and rigid
educational technological
programs that do noy reflect
the actual needs of the
industrial and countries in
the region
Lack of trust in govt.
authorities and ignoring of
existence of existing
environmental regulations.
Great differences in the
capacity to deal with
pollution prevention and
control between large
industries and SMEs.
Incomplete regulatory
framework and uneven
enforcement.
Inappropriate standards
copied from industrialized
countries.
Inefficient coordination
among different agencies at
different levels.
Poor mechanisms to
facilitate the establishment of
links with industries to
support technology
innovation.
Poor environmental
awareness among workers
and managers.
Government state owned
industrial have generally a
poor environmental
performance
Promotion criteria and
research funding are less
based on the practical
applicability of the research
and in the bridging efforts
between disciplines and
between university and
society.
Consultant firms use a
“technology colonization”
approach based on the import
of foreign technologies.
Lack of human resources and
infrastructure to support CP
programmes and to enforce
regulations.
Lack of an education policy
concerning environmental
education throughout the
educational programmers.
Cleaner Production in Textile industry scenario:
Cleaner production implementation practices applied in cooperation with state institutions and
organisations need to be increased and brought to scale.
Cleaner production speared and adopted at large we need to develop the relevant technical
capacity. It increases awareness of the approach and its benefits.
Textile industry adopted cleaner production processes se an increase in competitiveness due
to:
 Efficiency in resource utilization,

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 Decrease in production and waste management costs,
 Compliance with environment laws, regulations and relevant national strategies,
reducing the risk of fines,
 Increase brand value,
 Ability to benefit from the financial opportunities of national and international financial
institutions.
It is important for textile companies to reduce their dependency and impact on natural resources
to remain competitive and conserve the limited resources that are available. In recent years,
increasing productivity in production, replacing virgin raw material with those less harmful to
the environment, and reducing water and energy consumption in the processes of production
and use have been increasing rapidly.
Cleaner production benefits for business too. It covers Economical prospects. Their many
innovations done in private sector. Some major prospects are:
Increase in production efficiency: The efficient use of resources, more raw material becomes
a commercially- viable product. Reducing the use of energy, natural resources and raw
materials provides savings for the enterprise. Thus, production costs are reduced and more
production is possible with fewer raw materials. More efficient resource use can increase
production speed and competitiveness.
Reduction of waste treatment and disposal costs: Cleaner production practices reduce the
amount of waste generated during the production process. As a result, energy ad chemical use,
man power allocation, space requirements and disposal costs are reduced.
Environment Benefits:
Reduction of environment impacts: It provides efficient use of natural resources; minimization
of solid waste, wastewater and emission; and reduction of toxic contents. Thus, the negative
impacts of the production processes on humans and nature are reduced. It also positively to the
performance of the waste management infrastructure.
Support for companies with legislation today and preparation for the future: Cleaner production
practices are advantages in terms of compliance with applicable laws and regulations. It is the
general trend that environment legislation is becoming more demanding and is more often
enforced; This trend is very relevant in the case of china. If legislation changes, it may
expensive to adopt and impossible to comply, which may lead to more costs. But cleaner
production prepares enterprises for future regulations.
Social Benefits:
1. Safeguarding and building reputation
2. Support for occupational safety and worker health.
Environmental Impacts:
Water consumption: The textile uses a vast amount of water throughout the dyeing and
finishing processes and is among the largest consumes of water among all industries. The

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amount of water used to produce one kilogram of textile product can range from 95 to 400
litres.
Chemical Consumption:
The textile industry also draws attention with its high consumption of chemical substances.
The high chemical load in textile factories due to pre finishing, dying, finishing, sizing and
other processes varies according to the processes used. The total amount of chemical used in
textile can vary between 10% and 100% by weight of the textile product.
Wastewater Generation: Depending on the wet textile process in the facility, the wastewater
can vary. For example, wastewater resulting from de-sizing and finishing process can contain
high BOD (Biological Oxygen Demand), wastewater from bleaching can contain AOX
(Absorbate Organic Demand) and wastewater following painting processes can contain BOD,
COD (Chemical Oxygen Demand) and heavy metals.
Energy Consumption: Energy use is high dyeing and finishing processes, thread production,
and weaving constituting 19% of the total energy expenditure in industry. In the textile sector,
LPG and fuel oil are mostly used as fuel. For this reason, CO, SO2, NOx, aldehydes and dust
as present in the textile industry flue gas emission.
METHODS FOR CLEANER PROCUTION IN TEXTILE INDUSTRY:
 Facility Management: Establishment of an Environment Management system.
 Implementation of Environmental education programs.
 Preparation of annual waste inventory reports based on mass balances, showing all
substances inputs and outputs.
 Monitoring the quantity and quality of all inputs and outputs related to the production
process (raw materials, chemicals. Energy, water, products, wastewaters, air emissions,
sludge, solid wastes, hazardous wastes and by products.
 Storage of all chemical substances according to the instruction given on the safety
DATA sheets.
 Prevention of chemical spills, and in the event of a spill, the control and clean-up of the
area, preventing chemical spills from interfering with the environment or the sewage
system.
 General Measures: Automatic dosage and dispensing system for the dosage of
chemicals.
 When possible, manufacturing without chemical use.
 Where chemical use is essential, use of the chemical posing the least risk.
 The application of hydrogen peroxide under optimum conditions.
 Use of complex agents that can be easily biodegraded.
 Prevention of reduction in the use of antifoaming substances.
Raw material Selection: Consideration of the upstream environment impacts of fibres of
fibres and selection of the raw material with the least impact.
Man-made fibres: Select material treated with low-emission n biodegradable preparation
agents.

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Cotton: Select material sized with low add-on techniques (pre-wetting of the warp yarn) and
high efficiency bio eliminable sizing agents; use the available information to avoid processing
fibre material contaminated with the most hazardous chemicals such as PCB.
Wool: Use the available information to avoid processing fibre material contaminated with the
most hazardous chemicals such as pesticide residues; minimize at source any legally- used
sheep ectoparasitic ides. This can be done by encouraging the development of low pesticide
residue wool, by containing dialogue with competent bodies responsible for wool production,
and marketing in all producing countries; and select wool yarn spun with biodegradable
spinning agents instead of formulations based on mineral oils.
Water and Energy Management:
 Control and record keeping of water and energy consumption.
 The use of flow control devices and automatic shut-off valves in continuously running
machines.
 Using automatic equipment to check the volume and temperature of the baths in
intermittent working machines.
 To prevent waste of water and energy, documentation of the production procedures
should be available and it should be used by employees.
 Use of perpetual low input processes.
 Recovery of waste heat from waste gas and wastewater.
 Use of frequently-controlled electric motors.
Various Textile Production Processes:
Case studies of Cleaner production in the textile
sector:
Unit A: Textile process house located at Narol, Ahmedabad in the state of
Gujarat;
Washing
Finishing
Printing
Dyeing
Bleaching
Desizing
Pre-
finishing

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After the detailed visit of plant various options were generated for minimizing the generation
of wastes and consumption of materials, a total 38 CP opportunities are identified. Out of the
generated options, nine of them were directly implementable and 29 required further study.
CP result: The implementation of CP solutions resulted in both financial as well as
environmental benefits. The unit was able to benefits annually by about INR 85,67,712 through
the investment of INR 20,57,500.
Unit B; Textile process house located at Narol, Ahmedabad in the state of
Gujarat
In order to identify the opportunities for minimizing the generation of wastes and consumption
of materials, a total 35 CP opportunities are identified. Four of them were directly
implementable and 31 required further study.
CP results: The implementation of CP solutions resulted in both financial as well as
environmental benefits. The unit was able to benefit annually by about INR 13,05,750 thorough
the implementation of CP solutions, with an investment of INR 8,75,000.
Unit C: Textile process house located at Narol, Ahmedabad in the state of
Gujarat
In order to identify the opportunities for minimizing the generator of wastes and consumption
of materials, a total 10 CP opportunities are identified.
CP results: The implementation of CP solutions resulted in both financial as well as
environment benefits. The unit was able to benefit annually by about INR 10,14,240 through
the implementation of CP solutions, with an investment of INR 6,57,550.