1Bruxelles,
resource efficiency
22 Nov 2012
Factory management optimisation for energy
efficiency:
the ARTISAN project perspective
Innovation for resource efficiency
in the European Textile and Clothing Industry
22nd November 2012, Brussels
Piero De Sabbata
2Bruxelles,
resource efficiency
22 Nov 2012
Summary
� 1. Artisan project in a nutshell
� 2. Energy Efficiency in textile
industry
� 3. Artisan approach
2
3Bruxelles,
resource efficiency
22 Nov 2012
� ARTISAN� FP7 EU research project (STREP)
� Challenge 6 - ICT for a low carbon economy
� Call ICT-2011.6.2 ICT systems for energy efficiency
� November 2011 – April 2014
� OBJECTIVE reducing energy consumption and carbon emission by at
least 10% in textile industry through:
� Data capture technologies integration
� Process based energy monitoring
� Short time scale optimisation of
operations
� Supply chain and energy market
perspectives in the decision processes
The project
4Bruxelles,
resource efficiency
22 Nov 2012
� 1. Artisan project in a nutshell
� 2. Energy Efficiency in textile
industry
� 3. Artisan approach
4
Summary
5Bruxelles,
resource efficiency
22 Nov 2012
Scenario for textile industry
� External factors:
� Increasing energy costs
� Carbon emissions regulations
� Future energy market(s)
� Sectorial trends
� High competitivity and reduced
margins
� More flexibility and timeliness are
required
Challenge 1:
overcome opposition
Efficiency vs Flexibility
Challenge 2:
energy efficiency and carbon
emissions in day by day
operations and decisions
Challenge 3:
poor information about energy
costs in textile industry
Challenge 4:
From single machine efficiency
to supply chain efficiency
6Bruxelles,
resource efficiency
22 Nov 2012
Scenario for textile industry
� External factors:
� Increasing energy costs
� Carbon emissions regulations
� Future energy market(s)
� Sectorial trends
� High competitivity and reduced
margins
� More flexibility and timeliness are
required
Challenge 1:
overcome opposition
Efficiency vs Flexibility
Challenge 2:
energy efficiency and carbon
emissions in day by day
operations and decisions
Challenge 3:
poor information about energy
costs in textile industry
Challenge 4:
From single machine efficiency
to supply chain efficiency
Some figures from literature * :
� Thermal energy required per meter of cloth is 4,500-
5,500 KCal
� Electrical energy required per meter of cloth is 0.45-
0.55 KWh
* “Improving profits with energy-efficiency enhancements”, December 2008, Journal for Asia
on Textile and Apparel
7Bruxelles,
resource efficiency
22 Nov 2012
Scenario for textile industry
� External factors:
� Increasing energy costs
� Carbon emissions regulations
� Future energy market(s)
� Sectorial trends
� High competitivity and reduced
margins
� More flexibility and timeliness are
required
Challenge 1:
overcome opposition
Efficiency vs Flexibility
Challenge 2:
energy efficiency and carbon
emissions in day by day
operations and decisions
Challenge 3:
poor information about energy
costs in textile industry
Challenge 4:
From single machine efficiency
to supply chain efficiency
Some figures from literature * :
� Thermal energy required per meter of cloth is 4,500-
5,500 KCal
� Electrical energy required per meter of cloth is 0.45-
0.55 KWh
* “Improving profits with energy-efficiency enhancements”, December 2008, Journal for Asia
on Textile and Apparel
Some observed figures :
� Case of wool mill: from yarn to finished fabric total
energy (thermal+electric) 0,002 TOE/ m2 of fabric
(that is 24 KWh/m2)
…but…
are we aware of such figures?
are we sure these data apply to our plants?
8Bruxelles,
resource efficiency
22 Nov 2012
Samples
Action Cost
[€]
ROI /
10 years VAN
Energy saving
Heat recovering from 8
ton/h steam generator
38K 2 years / 120K
€
-5% total plant consumption
(finishing department)
New switching on policies
and revamping of 1 MW
(steam)
co-generators
290K 2,5 years/ 635K
€
-138.000 m3 methane,
equal to -7,5% total energy
consumption (finishing
department)
Steam generators, load
peak reduction
- - +5% efficiency (dyeing plant)
" and many other being discovered
Applying best practices and best available technologies to the concrete textile process
9Bruxelles,
resource efficiency
22 Nov 2012
the problem(s)
� Monitor real current use
and consumption
� Increase single process
efficiency
� Flatten load peaks
� Assume a supply chain
and societal perspective
10Bruxelles,
resource efficiency
22 Nov 2012
the problem(s)
� Monitor real current use
and consumption
� Increase single process
efficiency
� Flatten load peaks
� Assume a supply chain and
societal perspective
11Bruxelles,
resource efficiency
22 Nov 2012
the problem(s)
� Monitor real current use
and consumption
� Increase single process
efficiency
� Flatten load peaks
� Assume a supply chain and
societal perspective
12Bruxelles,
resource efficiency
22 Nov 2012
the problem(s)
� Monitor real current use
and consumption
� Increase single process
efficiency
� Flatten load peaks
� Assume a supply chain and
societal perspective
13Bruxelles,
resource efficiency
22 Nov 2012
� 1. Artisan project in a nutshell
� 2. Energy Efficiency in textile
industry
� 3. Artisan approach
13
Summary
14Bruxelles,
resource efficiency
22 Nov 2012
� Direct consumption
� Energy consumed by the production machines for
the production of an article
� Indirect consumption
� Energy consumed by non-process machine to
produce service fluids (compressed air, steam,..)
� Energy consumed by the other building facilities:
HVAC (heating, ventilation, air-conditioning),
lighting
� Efficiency in energy supplying (energy grids)
� Efficiency in supplying (electric) energy
A more global perspective
ARTISAN provides tools
allowing the decision
makers to tackle them in
a co-ordinated and non
separated way.
15Bruxelles,
resource efficiency
22 Nov 2012
Energy data capturingEnergy data capturing
Energy monitoringEnergy monitoring
Operations optimizationOperations optimization Energy ForecastingEnergy Forecasting
Energy TradingEnergy Trading
Carbon TradingCarbon Trading
ARTISAN Services
16Bruxelles,
resource efficiency
22 Nov 2012
The ARTISAN approach in a nutshell
Production
order
Materials
Productive
capacity
DSS:- Scheduler
- SCM
Monitoring- faults
- performance
Floor
Maintenance
Supply chain
Finished
Product
EMS:
- actual energy costs
- consumption Alarms
- consumption forecast
Green
Products and
certifications
- energy consumpt.Efficiency
projects
Energy & carbon permits trading
Energy
market and
suppliers
17Bruxelles,
resource efficiency
22 Nov 2012
Expected results
� Informative infrastructure to collect, store and communicate data on energy consumption at machine level;
� Energy performance indicators for textile industry, supported by services to analyze such indicators over the actual productive processes;
� Real time optimization algorithms for production planning and scheduling, address both cost reduction and energy saving;
� Energy forecasting on a daily base
� Energy and emission trading among partners of a supply chain or with external (Smart) Energy Grids;
� GUIDE for energy saving in textile industry to allow a first approach to energy efficiency and compare own company indexes with sectorial benchmarks
� A number of energy audits and two representative Field tests from the European Textile industry that demonstrate the results in real industry settings.
18Bruxelles,
resource efficiency
22 Nov 2012
Opportunities for textile industry to
collaborate
� registration at www.artisan-project.eu to get access to information, be
informed about workshops and results, social net initiatives…
� participation to the Industry Interest Group, co-ordinated by EURATEX, to
validate the foreseen scenarios and receive first hand information
� use “GUIDE for energy saving in textile industry” for free
19Bruxelles,
resource efficiency
22 Nov 2012
Thanks
� Contact: Piero De Sabbata,
� More information and registration to the mailing list
www.artisan-project.eu
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