MED TEST - TUNISIA An integrated Approach for Sustainable Production in the Textile Sector Rachid Nafti, Tunisia Euro-Mediterranean Conference on Digital integration, energy and resource efficiency: opportunities in textile and clothing value chains across the Euro-Mediterranean Area April 2015 at Kraków, Poland

TEST Training kit Table of contents Introduction of MED TEST initiative in the Textile sector Best practices and results Lessons learnt and replication

TEST Training kit 3 THE CHALLENGE Source: International Resource Panel, Decoupling Natural Resource Use and Environmental Impacts from Economic Growth, United Nations Environment Programme (UNEP), Nairobi, 2011 Resource use Human well-being Economic activity (GDP) Environmental impact Resource decoupling Impact decoupling Time Decoupling of Growth from Natural Resource Consumption and Negative Environmental Impacts

TEST Training kit Environmentally Sound Technology Cleaner Technology Pollution Prevention Waste minimization Resource Conservation End of Pipe Pollution Control Waste Treatment Resource Remediation Include both soft techniques (e.g. organizational measures) and Technologies Protect the environment Less polluting Use less resources per unit of product/service Recycle and handle residues in a more sustainable way Are safe with respect to the use of hazardous substances for humans and the environment TEST focus

TEST Training kit UNIDO TEST Programme The UNIDO transfer of Environmentally Sound Technology Programme to harness the full potential of Industry contribution to Inclusive and Sustainable Development (ISID)

TEST Training kit MED TEST I -Results > 760 RECP measures identified 54% measure PBP < 6 months 75% implementation rate MUSD investment 9.7 M m3 water savings/yr 263 GWh energy savings/yr Key Figures – Industry demonstrations Industry Fact sheets:

TEST Training kit Summary of MED TEST results in pilot textile companies Entreprise Investment (DT) Financial Gains (DT/an) Energy saving (%) Water saving (%) Savings in chemical products TFM : Textile finishing (Dyeing and bleaching) %40%25% GDS: Jean washing %24%10% GARTEX: Jean washing %19%11% TRAITEX: dyeing &jean washing %13%15% MEGASTONE: dyeing &jean washing %10%12% STARWASH: Jean washing %24%25% Total

TEST Training kit Performance evaluation Company Name Water ConsumptionElectricity consumptionNatural gas consumption Actual Consumption (l/kg) BAT (l/kg) Actual Consumption (Kwh/kg P) BAT (Kwh/kg P) Actual Consumption ( MJ/kg P) BAT ( MJ/kg P) TFM70,49 l/kg < 55– 65 l/kg 1,06 kWh/kg < 0,85 KWh/kg 34,03 MJ/kg 19 – 25 MJ/kg TRAITEX 66,05 l/kg <70–80 l/kg 0,97 KWh/kg < 0,8 KWh/kg 35,14 MJ/kg < 20 MJ/kg GARTEX 68 l/ kg < 55– 65 l/kg 0,52 kWh / kg < 0,4 – 0,5 kWh / kg 6,62 kg vapeur/kg < 4,5 – 5,5 kg vapeur/kg

TFM company: Description Heat fresh water to be introduced to the mercerising machine by heat exchanging with the discharged hot water=>recuperation of calories Water Consumption = m3/y Operational Savings Nm3/Y of natural gaz Heat recovery = Nm3/y Economic gain = TND ~ USD Environment al Savings Energy/Co Nm3/y Capital Investment 5000 USD PBP = 6.25 months SELECTED BEST PRACTICIES HEAT REACOVERY AT MERCERINSING MACHINE Heat exchanger hot water/steam Heat exchanger fresh water/hot water

ISULATION OF STEAM NETWORK Description Coating of Steam conducts by “laine de roche” and covering of the pipes by aluminium => isolation of the conducts Operational Savings 7% of energy heat consumption TND ~ USD Environment al Savings Energy/Co2 84 TEO/Y Capital Investment TND ~ USD Recovery time = 1year, one month TFM company Insulation material (laine de roche) Aluminium covering pipe

Description Recycling system of the caustic sauda used at the mercerising operation Operational Savings Quantity of NaOH = kg/y TND/y ~ USD Environmental Savings Chemicals (NaOH) = kg/Y Capital Investment TND ~ USD Recovery time = 1year, six months TFM company CAUSTIC SODA RECYCLING SYSTEM

GARTEX company Description For washing machines that have two exit pipes, rinsing water is recovered to be used in preparation process => water saving over 4 machines Operational Savings Water quantity = m3 Water recovering quantity = m3 Economic saving = TND ~ USD Environment al Savings Water saving = m3 Capital Investment TND ~ USD IRP = 15 months RECOVERY & REUSE OF RINSING WATER Dirty water exit Clean water exit for recuperation Recovered water tank

TEST Training kit MED TEST Added value for Industry Increased productivity, reduced operational costs, optimized investments; Minimized environmental compliance costs, reduced business risks and smaller environmental/carbon footprint; Compliance with international environmental standards for accessing new markets (global supply chains and export markets, new green markets, public procurement, etc.); Improved relationship with stakeholders (investors, banks, regulatory bodies, local communities, consumer associations, etc.).

TEST Training kit Lessons learnt 1.Assessing performance related to the use of raw materials, water, auxiliary materials and energy inputs as well as to the generation of major pollution outputs, and comparing them to industry sector benchmarks and international best practices, which often provides a good indication of achievable improvements. 2. Revealing the “total costs” of resource use inefficiencies within production and associated pollution through the quantification of non-product output costs (NPO costs). When considering NPO costs, the real environmental costs increase on average by one order of magnitude, which is usually very surprising to industry. 3. Installing an effective information system on the efficiency of material and energy flows, which helps identify new opportunities for improvement, monitor results and, last but not least, make people accountable for resource efficiency at the point where they influence it. Such information systems facilitate the linking of sustainable production through existing management system with the core business strategy.

TEST Training kit MED TEST II – Upscaling and replicating MED TEST pilot experience Stimulate the demand and supply of sustainable production services in the manufacturing sector

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