Garment and textile factories are the plants we audit most. Of the 80 facilities Hexa Engineering has audited in Bangladesh, 38 are apparel manufacturers, 14 are textile mills and 7 are garment washing plants: 59 in all. This page explains where these plants usually lose energy, what an audit measures in each area, and what to expect from the result.
Why garment and textile factories commission energy audits
- Energy is a large, controllable cost. Electricity, natural gas and fuel are among the biggest utility lines in knitting, dyeing, spinning and washing.
- Buyers ask for the data. International buyers increasingly ask suppliers for energy and emissions information, for example through Higg Index submissions and science-based targets. A measured baseline is where that starts. See our guide to SBTi for Bangladeshi factories.
- Regulation. Large energy consumers designated by SREDA must have periodic energy audits carried out by an accredited energy auditor under the Energy Efficiency and Conservation Rules, 2016. Read SREDA compliance and investment-grade energy audits.
- Finance. Bangladesh Bank's Green Transformation Fund (GTF) has supported energy-efficiency and renewable-energy projects at export-oriented textile and leather factories. Check the current terms with your bank. An investment-grade audit is the evidence behind such a loan.
Where a garment or textile plant uses energy
| Area | Main energy users | What the audit checks |
|---|---|---|
| Knitting, dyeing and finishing | Boilers, thermal oil heaters, stenters, dryers, dyeing machines, steam and hot water networks | Boiler efficiency from flue gas, steam traps and leaks, condensate return, insulation, heat recovery |
| Spinning | Large motors, ring frames, humidification and air conditioning, compressors | Motor loading and drives, HVAC and humidification plant, compressed air |
| Sewing and cutting | Lighting, ventilation and cooling, compressed air for machines | Lighting levels, air handling, air leaks and pressure settings |
| Garment washing | Steam, hot water, washers and dryers | Steam use per kilogram, hot water recovery, dryer efficiency |
| Utilities | Captive generators, chillers, air compressors, transformers | Generator efficiency, chiller performance, power factor, power quality |
Savings garment and textile plants commonly find
- Compressed air. Leaks, and pressure set higher than the machines need. Read more in compressed air and steam system optimization.
- Boilers and steam. Combustion tuning, failed steam traps, uninsulated pipes and condensate that is not returned.
- Waste heat recovery. Heat in boiler flue gas, generator exhaust and hot effluent that is currently lost.
- Motors and drives. Oversized motors, and fans and pumps that run at full speed when they do not need to.
- Power factor and power quality. Low power factor and harmonics that raise charges and stress equipment.
- HVAC and humidification. Controls and chiller operation, especially in spinning.
- Lighting. LED retrofit and zoning.
- Rooftop solar. Feasibility and payback. See solar PV ROI for factories in Bangladesh.
Which of these matters for your plant depends on how it runs. That is what the measurements decide.
How the audit works in a garment or textile plant
- Scoping visit. A day on site to walk the utilities and production lines and agree what the audit covers.
- Measurement. Loggers on the major loads, plus thermal, flue gas and air leak surveys over a full cycle. Measurement is done on live equipment, so production does not stop.
- Analysis. Every loss is quantified in kWh, taka and tonnes of CO2e, then ranked by payback.
- Implementation. Specifications, vendor evaluation and site supervision so the work is built as designed.
- Verification. We meter again against the baseline so your finance team can check the saving line by line.
What we have audited
38 apparel manufacturers, including knitwear, denim and flat knit plants, 14 textile manufacturers and 7 garment washing plants, across Dhaka, Gazipur, Savar, Ashulia, Narayanganj, Mymensingh, Chattogram, Habiganj and the export processing zones. The full list by sector is in our audit log.
What you receive
A measured baseline, a ranked list of savings measures with their saving, investment and payback, and a report signed by a certified energy auditor. Read what an energy audit report contains, or see what decides the cost.
To start, contact us and we will arrange a one-day scoping visit. Our main energy audit page has the full service description.