FUNDED BY THE EUROPEAN COMMISSION S ustainable and C leaner Production in the Manufacturing I ndustries of Pak istan SCI-Pak Mar Feb 2012

Water Consumption Figures  Water extensive industry (500-5,000 m 3 /d)  Specific water consumption ( liter/kg)

Water Consumption Estimation  Water turbine capacity and running hours  Process wise water consumption estimation (Recipe)  Wastewater flow monitoring (WW = 80% of fresh water consumption)  Production in meters x average width (m) x average GSM ÷ 1000 = kg

Water Wastages  Water is free and abundantly available  No water monitoring  Extensive washings (Fabric, Floor, drums)  Old inefficient machines (Automatic water shut off valves, co-current washing, leakages)  Wastages from water hoses  No reuse of steam condensate as boiler feed water

Water Wastages  Wastage of cooling water  No reuse of RO rejected and softener backwash water

 Water monitoring and its control  Reuse of cooling water (Heat exchangers, singeing, compressors, cooling drums, calenders, comfit, chillers, pumps etc)  Automatic water shut off valves  Countercurrent washings

 Reuse of steam condensate as boiler feed water  Reuse of RO rejected water and softener backwash water in wash rooms  Reuse of process washes (Scouring-desizing, mercerization-scouring & bleaching, bleaching- scouring)  Water shut off valves at water hoses  Reuse of colored water for washing color kitchen floor, printing machine accessories and pigment drums

 Optimum consumption: m 3 /ton of hides  Higher consumption (no water conservation measures): 350-1,000 m 3 /ton of hides #Tanning ProcessWater Consumption (%) 1Soaking Liming De-liming & Bating8-12 Total Beam House Pickling & Tanning7-15 5Re-tanning, Dyeing, Fat Liquoring8-14 Total Tanning and Post Tanning15-29

 Running washes  No float control (No measurement of water being fed into the drum)  Generally high float is maintained, % more (to be on the safer side)  Floor washing, self bathing with the large diameter pipeline  Leakages in the water pipelines  Steam condensate is wasted  More washes are required for salted hides in the soaking process

 Batch washes  Water measurement with water flow meters  Low float (Optimum)  Separate small diameter pipeline for floor washing and self bathing  Leakage control  Use of desalted hides (20% water saving)  Reuse of steam condensate