Wastewater Treatment System
We are blessed with abundant natural fresh water by Wastewater Treatment System. Availability of such fresh water has made things easier for us to do fabric processing businesses in such a small country. However, we use thousand liters of water for dyeing and other purposes every day. The more water we use, the more wastewater or liquid waste is generated from our fabric processing machines every day unlike other wastes. Sludge Recycle of ETP
Textile wastewater (water mixed with different dyes & chemicals) requires systemic treatment by effluent treatment facility. Hence, wastewater is a big issue for any textile industries. We have our own ETP (effluent treatment plant) to treat our wastewater. We are doing the following research & development activities to minimize or reduce wastewater-
Review meeting is held every three month regarding previous decisions and upcoming decisions to make. Our General Manager (GM) advises this meeting. Every waste management related issue is openly discussed and shared. Brainstorming and new idea sharing are done so that corrective actions can be taken in procedure level. We always consider 3R principle (Reduce, Reuse & Recycle) whether we can implement this idea in any aspect of waste management.
Adjusting Liquor Ratio:
Changing Liquor Ratio is another way to save water and chemicals during wet processing which is ultimately Waste or Wastewater Reduction step is taken by our innovative Waste Management Team. Changing Liquor Ratio should be encouraged as it can decrease concentration of dyes & chemicals in the wastewater. Otherwise alternative chemical should be adopted, which requires less Liquor ratio. For example, we use Avitera SE -the dyestuff of Huntsman after Technology Assessment, which is marketed by Huntsman under the logo of Save the Earth. We also use third generation Wash off like Dekol RSA (Resource Saving Agent) and Crosscolor BCSR, which help us to save natural resources like water. We always look for better innovations than the above-mentioned dyestuffs in the market.
Awareness building up can save a lot resources and helps to reduce waste generation. Imparting training program may help workers & employees to be more conscious about resource management & waste management. Ideas should be discussed and shared among workers. Little awareness can save lots of paper, dyes, chemicals & water every day. We have posted awareness building up posters on appliances use, water consumption and energy efficiency in many places of our factory premises so that awareness among the workers can be developed and energy efficiency & better waste management practices may rise thereby.
Water is the vital resource for fabric processing. So water consumption should be properly metered. We cannot manage waste consumption without measuring. Total consumption and total disposal of wastewater should be metered. Furthermore, section wise water consumption record should be kept so that assessment and analysis of wastewater can be done properly. We have two inlets for our dyeing section and two flow meters installed on that inlet give us water consumption data.
Fabric processing is a continuous cycle, which involves a lot of chemicals & dyes. A slight change in the fabric recipe can save a lot of chemical/dyes, water and reduce wastewater generation rate. Our production team optimizes the dosage of chemical/auxiliaries by trial and error method. For example, if we use a detergent 1gm/liter, then it is deducted by 10% (.1gm) and some trial batches (by .9gm/liter) are executed. The reports of the batches are reviewed and process designed is Redefined. Dosage Optimization of every chemical/dye is done by this way without deteriorating the quality. Existing process design is re-evaluated if any single process step can be skipped to form new process design which might help to generate less wastewater. our production team re-engineer the process step whether it could be possible to eliminate the rinsing by a single filled wash drain cycle and if it is viable for wastewater reduction. Same importance is given to both energy consumption and natural resources. Our Senior Manager (Production) continuously generates concepts and monitors the overall dyeing process if consumption of dyes & chemicals could be decreased in order to minimize waste water as well. Forming new process design cannot be done in a day or month. Continuous efforts are required for this.
Technological assessment & advancement can help us to save our time, money & resource and generate lesser waste. Existing processing system should be assessed & analyzed if existing machineries can support lowest Liquor Ratio. Old and backdated machineries should be replaced if possible in order to minimize liquid waste or wastewater generation, which is a big issue for textile industries. Our team always looks for any innovations regarding dyestuff, dye auxiliaries that may help to reduce liquor ratio and skip wash cycle, e.t. waste prevention initiative.
If any advanced technology is available in the market, our team tries to figure out the pons & cons and efficiency of that technology and discusses with entrepreneurs about the viability of that Wastewater Treatment System