Increasing the condensate recovery by 37% for a garment manufacturer using EverSense for Plant-wide Performance

A prominent garment manufacturer and exporter in Tamil Nadu, India was unable to achieve their net-zero goals over the last two years. With steam intensive processes such as iron baths and tumble dryers, they found it difficult to identify and sustain energy-saving opportunities. Global buyers in the garment industry have mandated meeting specific sustainability targets, and hence as a supplier, meeting the mandate deadline was essential.

To address this challenge, our Forbes Marshall Digital partnership with this garment plant began in August 2024 with a shared objective of improving efficiency, enhancing CRF, and supporting their journey towards net-zero using EverSense for Plant-wide Performance.

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PROBLEM

Condensate Recovery Factor (CRF) was below 30% against the benchmark of 52%.

Despite efforts made, they were unable to identify avenues to meet buyer-specified sustainability metrics.

SOLUTION

Digitally monitoring key parameters such as specific steam consumption (SSC), condensate recovery, steam consumption, total consumption and CRF using the EverSense dashboard enabled real-time and daily data tracking for performance visibility.

Faster identification of the specific pumps where the condensate recovery has reduced, enabled timely corrective action.

Trend analysis and root cause identification done when SSC rises enabled prompt corrective action restoring efficiency and preventing excess steam consumption.

On-site checks complement 24×7 digital monitoring, ensuring that plant operations run smoothly. This dual digital and physical approach enabled continuous improvement and sustenance.

Replaced single pump with 2+2 configuration for balanced steam distribution and reduced load.

Routed condensate back to the feedwater tank for reuse, improving feedwater temperature and reducing fuel demand.

Re-insulated main steam lines to minimise radiation losses.

Installed G-traps to prevent steam loss and recover condensate back to the feedwater tank.

BENEFITS

Steam consumption reduced from 6,471 to 5,065 Kilograms/day (14K to 11K Pounds/day), achieving a 22% reduction and moving closer to the benchmark of 4,810 Kilograms/day (10K Pounds/day).

Specific steam consumption (SSC) brought down from 0.12 to 0.1 Kilograms/piece (0.3 to 0.2 Pounds/piece), matching the benchmark.

CRF improved from 35% to 48%, reaching the benchmark range of 47–52%.

Feedwater temperature sustained at 91°C (95.8°F), within the benchmark range of 90-95°C (194-203°F).

Overall reduction in steam usage and improved CRF directly contribute to the plant’s net-zero goals and reduced carbon footprint.