In today’s competitive garment industry, efficiency isn’t just a luxury—it’s a necessity. For mid-size garment factories, the pressure to reduce production costs while meeting global sustainability standards is stronger than ever. One powerful solution that addresses both these challenges is the implementation of an Energy Management System (EMS).
An Energy Management System helps factories monitor, control, and optimize energy consumption across departments—from boilers to sewing lines to finishing areas. While large-scale garment manufacturers often have the capital and resources to adopt high-end EMS solutions, mid-size factories often overlook the opportunity, assuming it’s too complex or expensive.
But this assumption is outdated.
Modern EMS technologies have become more accessible and customizable for mid-tier operations. With proper planning and phased implementation, mid-size garment factories can save up to 30% in energy costs, improve their operational efficiency, and achieve certifications like ISO 50001, which boosts their market reputation—especially among buyers prioritizing ESG compliance.
This blog post will guide you through:
- What an Energy Management System is and how it works in the garment sector
- Why EMS is critical for mid-size operations in today’s global apparel supply chain
- How to implement EMS step-by-step, from energy audits to full ISO 50001 certification
- Real-world case studies and practical examples (including EMS Apparels Ltd, Bangladesh)
- Financial benefits, operational improvements, and quick-win strategies
- How to overcome common challenges during EMS rollout
Understanding EMS & ISO 50001
What is an Energy Management System (EMS)?
An Energy Management System (EMS) is a structured framework that allows factories to measure, monitor, control, and improve their energy consumption. Think of it as a central nervous system that tracks where energy is used, identifies inefficiencies, and helps take action to optimize usage.
In the garment manufacturing context, EMS can include:
- Smart meters for tracking real-time electricity, gas, and steam usage
- Energy dashboards that visualize consumption patterns
- Automation tools to optimize equipment operation (like HVAC or compressors)
- Alerts and KPIs for identifying abnormal usage and energy leaks
EMS is not just a software or a meter—it’s a combination of:
- Technology (sensors, analytics, automation),
- Processes (energy audits, performance monitoring, reporting), and
- People (trained energy managers, production teams, and leadership support).
By tracking energy use at every stage of production—from spinning and dyeing to finishing and packaging—factories gain data-driven insights that help lower energy bills, reduce carbon emissions, and meet buyer expectations.
Overview of ISO 50001: The Gold Standard for Energy Management
To bring structure and international credibility to EMS practices, many garment factories are adopting ISO 50001, the globally recognized standard for energy management.
What is ISO 50001?
ISO 50001 is an international standard that provides a proven framework for setting up an EMS. It’s built on the Plan-Do-Check-Act (PDCA) model—meaning it’s designed for continuous improvement.
Key elements of ISO 50001 include:
- Establishing an energy policy aligned with factory goals
- Identifying key energy-consuming processes (called Significant Energy Uses or SEUs)
- Setting measurable Energy Performance Indicators (EnPIs)
- Implementing controls and improvement projects
- Monitoring and reviewing progress through audits and reviews
- The standard helps garment factories:
- Cut down energy waste and operational costs
- Align with international buyer sustainability programs
- Access green financing and subsidies (e.g., IDCOL, IFC programs in Bangladesh)
- Boost market reputation and buyer confidence
How EMS & ISO 50001 Complement Each Other
While EMS is the practical system for managing energy in real time, ISO 50001 is the strategic framework that ensures this system is robust, repeatable, and continuously improving.
Here’s how they work together:
| EMS Component | ISO 50001 Framework |
| Smart meters, dashboards | Supports data collection for KPIs |
| SOPs, reports, checklists | Align with required documentation |
| Staff training & awareness | Required for continual improvement |
| Energy audits | Integral to ISO’s planning phase |
| Monitoring & verification | Required in ISO’s “Check” stage |
For mid-size garment factories, adopting EMS practices with ISO 50001 alignment can unlock both technical and strategic benefits—from reducing energy bills to qualifying for international certifications and green export labels.
EMS Implementation Steps in Garment Factories
Implementing an Energy Management System (EMS) doesn’t happen overnight—it requires a structured approach tailored to the specific operations and scale of the factory. For mid-size garment units, a phased rollout is often the most cost-effective and practical path.
Here’s a step-by-step guide to help factories implement EMS effectively:
Step 1: Conduct an Initial Energy Assessment & Set a Baseline
Before anything else, understand how energy is currently used.
Actions:
- Perform a comprehensive energy audit to identify energy flows and waste points.
- Categorize energy usage by department: lighting, sewing lines, dyeing units, boilers, air compressors, HVAC, etc.
- Set a baseline using EnPIs (Energy Performance Indicators)—e.g., kWh per 1,000 garments or steam usage per kg of fabric.
Tools:
- Handheld energy meters
- Infrared thermography
- Data loggers and submeters
Example: A factory in Gazipur found that its boiler system was consuming 40% of total energy—primarily due to poor insulation and outdated controls. Identifying this early saved them 22% in steam costs after improvements.
Step 2: Define Energy Policy & Assign Roles
Leadership involvement is critical. Without top-down support, EMS efforts often stall.
Develop:
- An Energy Policy stating the company’s commitment to improving energy efficiency.
- Roles and responsibilities for each department—especially maintenance, production, and utility management.
Establish:
- An Energy Management Team
- Clear ownership of EMS data, reporting, and KPIs
Step 3: Build Technical & Data Infrastructure
Once roles are defined, begin installing or upgrading the tools that gather real-time data.
Install:
- Smart meters for key equipment and zones
- Submetering for specific utilities (e.g., compressors, boilers, HVAC, dyeing machines)
- Central dashboard or software for visualizing energy trends
Add Analytics:
- Load profiles and time-of-day consumption
- Automated alerts for deviations
- Comparison vs. benchmarks or past data
For mid-size factories, start with high-energy-use areas (like boilers or dyeing machines) before scaling across departments.
Step 4: Identify & Implement Energy Efficiency Measures
Now that the data is flowing, analyze it to find savings opportunities.
Common Measures:
- Replacing fluorescent lights with LEDs
- Installing Variable Frequency Drives (VFDs) on motors
- Improving insulation on steam lines
- Optimizing compressed air systems to reduce leaks
- Adjusting HVAC set points during non-production hours
Advanced Measures:
- Heat recovery from exhaust gases
- Solar rooftop panels or hybrid renewable setups
- BMS (Building Management Systems) for automated control
Case Insight: A Chattogram-based woven factory saved over $16,000/year by simply optimizing its air compressor settings and fixing leaks.
Step 5: Train Staff & Drive Energy Awareness
A system is only as good as the people running it.
Train Teams On:
- Equipment shutdown schedules
- Optimal machine settings
- Energy-saving SOPs
- Data reporting tools
Methods:
- Visual reminders (posters, charts)
- Energy awareness days or competitions
- Weekly department-level dashboards
- Human behavior can account for up to 10% of total savings—without any capital investment.
Step 6: Document, Review, and Audit
For sustained impact, EMS must be continuously reviewed and refined.
Maintain:
- Documentation of audits, procedures, and savings
- Monthly reports comparing actual vs. target consumption
- Logs of energy-saving projects
Conduct:
- Internal audits of energy practices
- Quarterly management reviews
- Gap analysis if aiming for ISO 50001 certification
Step 7: Certification (Optional but Strategic)
While not mandatory, ISO 50001 certification offers credibility, global recognition, and buyer trust.
Steps:
- Conduct pre-certification assessment
- Engage with an accredited local certifying body
- Complete Stage 1 and Stage 2 audits
- Fix non-conformities (if any)
- Receive ISO 50001 certificate
🇧🇩 Certification Bodies in Bangladesh Include:
- BSTI
- BSI Bangladesh
- SGS
- TÜV SÜD
Buyers like H&M, C&A, and Uniqlo increasingly value ISO 50001 certification in their supplier evaluations.
With EMS in place and running, the next step is to explore what performance metrics and best practices mid-size factories should focus on for long-term results.
Key Energy Performance Measures & Best Practices
An Energy Management System (EMS) is only effective when it’s built around clear, actionable metrics and backed by proven best practices. Mid-size garment factories can achieve impressive results by focusing on performance indicators and systematically adopting energy-efficient strategies tailored to their production environment.
Key Energy Performance Indicators (EnPIs)
To measure improvement, you must track performance over time using Energy Performance Indicators (EnPIs). These indicators help you assess energy intensity, identify high-consumption areas, and monitor the impact of your energy-saving initiatives.
Common EnPIs for Garment Factories:
- kWh per 1,000 garments produced
- Steam (kg) per kg of fabric dyed
- Compressed air consumption per sewing line per shift
- Energy cost as % of total production cost
- Monthly CO₂ emissions per production unit
Good Practices:
- Set EnPI benchmarks by machine or process
- Monitor EnPIs monthly (or weekly for high-load areas)
- Use visuals—charts, dashboards—for team awareness
- Compare actual vs target, and explain deviations
Example: A knitwear factory set a target of 45 kWh per 1,000 garments. After introducing LED lighting and shutting off idle compressors, they brought it down to 38 kWh—translating to over $12,000 in annual savings.
Regular Audits & Monitoring
Energy efficiency is not a “set-it-and-forget-it” initiative—it requires ongoing auditing and active monitoring.
Audit Types:
- Daily walk-throughs to spot leaks, overheating, poor shutdown practices
- Monthly utility bill audits to compare actual vs expected consumption
- Annual comprehensive audits using third-party consultants or ISO 50001 requirements
Continuous Monitoring Tools:
- Smart meters with cloud connectivity
- BMS-integrated dashboards
- Thermal imaging cameras to detect heat loss
- Alarm triggers for equipment overuse or leaks
- Audits are often the fastest way to spot hidden losses—up to 20% of energy can be wasted silently without these checks.
Renewable Energy Integration
Mid-size garment factories are increasingly integrating on-site renewable energy systems—most notably solar rooftop installations.
Solar Rooftop:
- Reduces grid dependency and peak-load charges
- Offers payback within 3–6 years with proper financing
- Requires net metering policy awareness (available in Bangladesh)
Biomass & Biofuel Boilers:
- Use organic waste, jute sticks, or husks
- Lower carbon footprint compared to diesel or gas boilers
- Often eligible for green finance subsidies
Hybrid Systems:
- Combine solar + biomass for better load coverage
- Reduce reliance on fossil fuels
EMS Apparels Ltd. installed a 150 kWp rooftop solar system in Gazipur. It generates 180,000+ kWh annually and reduces 9,580 tons of CO₂ emissions over its lifecycle.
Steam & Heat Efficiency
In most garment factories—especially dyeing or washing units—steam and heat account for 30%–50% of total energy costs.
Solutions:
- Recover waste heat from boilers and exhaust systems
- Insulate steam lines to minimize loss
- Use steam traps to improve boiler efficiency
- Shift to electric or biomass-fired boilers with better thermal control
A mid-size denim unit saved 18% of its thermal energy after recovering exhaust heat to preheat feed water.
Equipment Optimization
Many machines in garment factories run at full capacity regardless of demand. EMS helps match energy usage to actual production needs.
Key Optimization Ideas:
- Install Variable Frequency Drives (VFDs) on motors, pumps, and fans
- Optimize sewing machine settings and idle-time power-offs
- Use programmable timers for lights, exhausts, and HVAC
Production Load Balancing:
- Shift heavy-load operations to off-peak hours
- Group similar processes for efficient energy use (batch processing)
- Avoid simultaneous startup of large equipment
Infrastructure Efficiency
While process-related savings are essential, the physical infrastructure also offers significant opportunities.
Upgrade:
- Lighting: Shift to LED with motion sensors
- Ventilation: Improve airflow and reduce HVAC overuse
- Insulation: Roof and wall insulation reduces heat ingress
- Daylighting: Use skylights and reflective paint to reduce artificial lighting needs
Green Building Elements (LEED or EDGE standards):
- Low-E glass
- Water reuse systems
- Natural ventilation designs
Some Bangladeshi factories have used these upgrades to achieve LEED Platinum status and slash energy consumption by over 40%.
Case Study: EMS Apparels Ltd (Bangladesh)
To understand the real-world benefits of implementing an Energy Management System (EMS), we can look at a model performer: EMS Apparels Ltd., a Bangladeshi garment factory that has successfully integrated sustainable energy practices into its operations.
Factory Overview & Sustainability Credentials
EMS Apparels Ltd. is a mid-sized, export-oriented garment factory located in Gazipur, Bangladesh. It specializes in knitwear and woven products, catering to global brands.
What sets EMS Apparels apart is its deep commitment to sustainability and energy efficiency, which is evident in its certifications and infrastructure:
- LEED Platinum Certified by the U.S. Green Building Council
- Fully compliant with ISO 14001 (Environmental Management) and ISO 45001 (Occupational Health & Safety)
- Integrated Energy Management System aligned with ISO 50001
The company has designed its production environment to minimize energy waste while maximizing performance and compliance with international buyer standards.
Renewable Energy in Action
One of EMS Apparels’ flagship energy initiatives is its 150 kWp rooftop solar power plant.
Solar Project Highlights:
- Installed in partnership with GreenTech Energy Ltd. in 2023
- Generates 180,000+ kWh annually
- Offsets approximately 9,580 tons of CO₂ emissions over its lifecycle
- Supplies clean energy to sewing floors, lighting systems, and office areas
The project has significantly reduced EMS Apparels’ dependency on grid electricity and diesel backup generators—leading to consistent operational cost savings and enhanced resilience during power fluctuations.
“Our solar energy integration is not just about reducing costs—it’s about future-proofing our business and meeting buyer sustainability goals.”
— Factory Energy Manager, EMS Apparels Ltd.
Energy Optimization Across Departments
Beyond solar, EMS Apparels has embraced energy efficiency across its operations through EMS-aligned practices:
Implemented Upgrades:
- VFDs (Variable Frequency Drives) installed on air compressors and exhaust fans
- Energy meters installed in 12 key departments for granular tracking
- Real-time energy dashboards displayed in production zones
- Steam line insulation and boiler optimization programs
- LED lighting across all production floors and warehouses
These upgrades resulted in:
- 27% reduction in electricity usage per garment
- 18% reduction in steam consumption
- Less than 3-year payback period for all energy investments
Organizational Impact & ESG Alignment
EMS Apparels’ energy strategy is part of a broader Environmental, Social, and Governance (ESG) commitment.
Environmental Impact:
- Reduced carbon footprint
- Responsible waste heat management
- Compliance with buyer codes of conduct (H&M, Zara, C&A)
Social Benefits:
- Cooler working environment due to better HVAC control
- Employee training on energy awareness and safe practices
- Recognition as a preferred employer for sustainable values
Governance & Market Impact:
- Enhanced buyer trust and repeat orders
- Fast-tracked listing in global sustainable sourcing platforms
- Positioned as an industry leader in Bangladesh’s green RMG movement
EMS Apparels’ success story proves that mid-size garment factories can lead in energy efficiency without compromising profitability or production quality.
Financial & Operational Benefits
For many mid-size garment factories, the decision to implement an Energy Management System (EMS) hinge on one key question: What’s the return on investment?
The truth is—the financial and operational benefits are both substantial and measurable. Factories that invest in EMS not only lower their energy bills but also gain long-term operational resilience, regulatory readiness, and a better brand image in the eyes of global buyers.
Cost Savings & Return on Investment (ROI)
One of the most immediate benefits of EMS is direct energy cost reduction.
Key Financial Impacts:
- 10%–30% savings in electricity and steam bills, depending on baseline inefficiencies
- Reduced equipment maintenance costs due to better system monitoring
- Shorter payback periods for upgrades (typically 1.5–3 years)
- Improved eligibility for green finance or low-interest loans (e.g., from IDCOL, IFC)
Sample ROI Calculation:
| Upgrade | Initial Cost | Annual Savings | Payback Period |
| LED Lighting Retrofit | $5,000 | $2,200 | 2.3 years |
| VFD for Compressors | $3,800 | $1,600 | 2.4 years |
| Solar Rooftop (100 kWp) | $90,000 | $15,000 | 6 years |
| Steam Line Insulation | $2,000 | $1,000 | 2 years |
When bundled with energy monitoring tools, these projects also improve visibility and accountability across departments—further reducing waste.
Operational Efficiency & Production Stability
Energy savings are only part of the story. EMS also enhances how a factory functions day to day.
Operational Improvements:
- Reduced downtime from better equipment diagnostics and preventive maintenance
- Improved production scheduling based on real-time energy data
- More efficient use of utilities like air compressors, boilers, and HVAC
- Lower risk of overloading during peak demand times
A woven factory in Narayanganj reduced machine idle time by 12% after installing a smart EMS dashboard that alerted staff when machines were left running.
Environmental Benefits & Compliance
Sustainability is no longer a buzzword—it’s a business requirement. Buyers from the EU, North America, and Japan increasingly expect proof of environmental responsibility.
Environmental Impact of EMS:
- Reduced carbon emissions by lowering fossil fuel use
- Better waste heat recovery and lower thermal pollution
- Data-driven ESG reporting to meet buyer demands
ISO 50001-certified factories can demonstrate:
- Measurable progress in energy performance
- Transparent environmental management
- Compliance with global buyer sustainability goals (like Higg Index or ZDHC)
Brand Value, Buyer Confidence & Market Access
In a competitive export market, EMS can give mid-size factories a powerful edge.
Buyer-Focused Advantages:
- Recognition by brands like H&M, Uniqlo, C&A, and Bestseller
- Inclusion in sustainable sourcing databases (e.g., Open Apparel Registry, Sedex)
- Improved scores on social and environmental audits
- Increased visibility during vendor selection and capacity expansion
Buyers are increasingly ranking factories based on their energy and sustainability metrics—not just price and lead time.
Worker Welfare & Compliance with Labor Laws
Improved energy management also translates into better working conditions—a critical part of social compliance.
Benefits for Workers:
- Reduced indoor temperatures through HVAC optimization and insulation
- Lower exposure to fumes or steam leaks
- Improved lighting quality, leading to fewer errors and better productivity
- Enhanced compliance with local labor laws and EU buyer guidelines on worker health and safety
According to a 2024 Reuters study, poor factory ventilation and overheating are among the top risks facing garment workers in Asia. EMS directly addresses these.
In summary, EMS is not just an energy-saving tool—it’s a business enabler. It unlocks cost savings, production efficiency, brand equity, and workforce wellbeing—all at once.
Challenges & Solutions for Mid-Size Garment Units
While the benefits of Energy Management Systems (EMS) are clear, mid-size garment factories often face practical challenges when trying to implement them. These challenges can include limited capital, lack of technical expertise, or operational resistance—but the good news is, each challenge has a proven solution.
Challenge: Limited Capital & Budget Constraints
Problem:
Mid-size factories often work on thin margins. The upfront cost of meters, software, solar panels, or energy audits may seem too high, especially if they lack financing options.
Solution:
- Start small with low-cost improvements like LED lighting or insulation
- Apply for green financing programs (IDCOL, SREDA, IFC, GCF) that offer subsidized loans or grants
- Use performance-based payback models for solar (CAPEX vs OPEX)
- Bundle projects into a phased investment plan spread over 12–36 months
EMS doesn’t have to start with high-end software. Even Excel-based tracking and smart submeters can create measurable savings from Day 1.
Challenge: Lack of Technical Expertise
Problem:
Mid-size factories may not have in-house engineers trained in EMS or ISO 50001, and external consultants can be expensive.
Solution:
- Use free or subsidized EMS training programs (e.g., from GIZ, IFC PaCT, SREDA)
- Appoint an internal “Energy Champion” and upskill them via short courses
- Partner with local universities or NGOs offering technical support
- Start with simple, visual tools (dashboards, color-coded trackers) that don’t require coding or engineering backgrounds
Challenge: Operational Resistance
Problem:
- Line managers or staff may resist changes like equipment shutdown protocols, machine schedule adjustments, or new reporting practices.
Solution:
- Involve all departments during EMS planning to reduce pushback
- Highlight cost savings as team achievements—give recognition and rewards
- Use visual dashboards on the production floor to create healthy competition
- Start with “quick wins” (e.g., turning off idle machines or fixing compressed air leaks) that build momentum
Behavioral change is the toughest but most cost-effective step. Start with a “why” and keep showing results.
Challenge: Data Collection & Analysis Barriers
Problem:
- Without reliable meters, many factories struggle with accurate energy data. Manual logs may be incomplete or inconsistent.
Solution:
- Begin with submetering for high-energy-use areas (e.g., boiler, compressors)
- Use offline data loggers if real-time dashboards are unaffordable
- Implement a simple weekly reporting system using Excel or Google Sheets
- Gradually shift to smart meters and automated reports as ROI becomes visible
- You don’t need 100% data coverage to make smart decisions—just track the top 20% of equipment responsible for 80% of energy use.
Challenge: Certification Complexity (ISO 50001)
Problem:
- Many factories are overwhelmed by the documentation, audit prep, and resources required to get ISO certified.
Solution:
- Focus first on EMS best practices, even if certification isn’t immediate
- Use pre-assessment tools or mock audits to prepare gradually
- Partner with local consultants or certifiers offering bundled packages
- Align your EMS structure with PDCA cycle so that ISO 50001 becomes a natural progression, not a separate project
Think of ISO 50001 as a long-term destination, not a starting line. Focus first on performance—certification can follow naturally.
Roadmap for Small/Mid‑Size Garment Factories
Implementing an Energy Management System (EMS) in a mid-size garment factory doesn’t require a massive overhaul. The key is to take a phased, structured, and scalable approach that builds momentum while managing cost and complexity.
Here’s a step-by-step roadmap tailored specifically for mid-sized factories in Bangladesh and other developing economies.
Phase 1: Awareness & Internal Engagement (Month 0–2)
Objectives:
- Build awareness of energy’s impact on cost and compliance
- Create internal buy-in for EMS activities
Key Actions:
- Conduct an introductory training/workshop for key staff
- Identify an Energy Manager or EMS Champion
- Set initial goals (e.g., 10% reduction in boiler fuel use)
- Start manual tracking of energy bills and production output
Phase 2: Baseline Assessment & Low-Cost Measures (Month 2–4)
Objectives:
- Identify major sources of energy use and waste
- Implement simple, quick wins
Key Actions:
Perform an internal energy walk-through audit
Measure baseline use for:
- Steam (boiler)
- Compressed air
- HVAC systems
- Lighting
Fix leaks, insulate steam lines, and schedule machine shutdowns
Start logging data weekly in Excel/Google Sheets
Most factories can cut 5–10% energy use in this phase without any equipment purchases.
Phase 3: Submetering & Monitoring Tools (Month 4–6)
Objectives:
- Enhance visibility and accountability
- Move from estimation to actual measurement
Key Actions:
Install basic submeters on:
- Compressors
- Generator/Diesel
- Boiler feedwater
Use digital tools (like Excel dashboards or open-source platforms) to analyze trends
Set up monthly review meetings to discuss EMS metrics
Develop SOPs for machine use, shutdowns, and maintenance
Share energy data in daily production meetings—make energy part of the floor culture.
Phase 4: Intermediate Investments & Staff Training (Month 6–12)
Objectives:
- Begin investing in upgrades with clear ROI
- Build internal technical capacity
Key Actions:
Retrofit with:
- VFDs (Variable Frequency Drives)
- LED lights
- Efficient motors or pumps
Conduct external EMS training for the energy team (e.g., from PaCT, GIZ)
Pilot one energy-saving project per quarter
Align EMS efforts with buyer expectations or CSR audits
Prioritize upgrades that reduce both energy use and compliance risk (e.g., ventilation fans, fume extraction).
Phase 5: Strategic Scaling & ISO 50001 Readiness (Year 2+)
Objectives:
- Institutionalize EMS across the organization
- Prepare for formal recognition and buyer reporting
Key Actions:
- Develop a written energy policy
- Map all energy-consuming processes with performance indicators (EnPIs)
- Prepare for third-party audits (ISO 50001, Higg FEM, etc.)
Integrate EMS with:
- Production planning
- Maintenance schedules
- Buyer scorecard reporting
ISO 50001 readiness is a long-term goal—but your buyers will appreciate visible progress even before certification.
Bonus: Free Tools and Support Available in Bangladesh
- SREDA & IDCOL: Grants and loan schemes for energy efficiency
- IFC PaCT: Energy audit support, buyer-backed EMS training
- GIZ & BGMEA: Webinars, workshops, and toolkits
- BUET & DUET: Academic collaboration for system design
By following this roadmap, a mid-size garment factory can transform energy management from a cost center to a competitive advantage, while aligning with global buyer priorities.
Case Studies of EMS in Mid-Sized Garment Factories
To help you visualize the real-world impact of Energy Management Systems (EMS), here are detailed case studies of Bangladeshi and regional mid-size garment factories that implemented EMS successfully. These examples cover practical steps, investments, results, and lessons learned—giving you proof that EMS works, even without big budgets.
Case Study 1: Knitwear Factory in Narayanganj
Factory Profile:
- Type: Knit composite
- Workforce: ~1,000 workers
- Monthly Output: 300,000 pcs
- Initial EMS Status: None (manual energy tracking)
Steps Taken:
- Appointed internal “Energy Champion” from the maintenance team
- Started weekly meter readings (diesel, steam, electricity)
- Fixed major steam leaks, insulated 60% of steam pipelines
- Installed timer-based lighting in production floors and washrooms
Results After 6 Months:
- Boiler fuel consumption down by 12%
- Electricity cost reduced by 7%
- No investment beyond insulation and staff time
Case Study 2: Woven Shirt Factory in Gazipur
Factory Profile:
- Type: Mid-sized woven unit (export-focused)
- Monthly Output: ~250,000 pcs
- Previous Issues: High compressed air consumption, old motors
EMS Actions:
- Submetered air compressor room and sewing section
- Trained operators on compressed air leak identification
- Installed VFDs on exhaust fans and air compressors
- Began using EnPI (Energy per piece) as KPI for production
Results:
- Compressed air leak reduction saved Tk. 1.2 lakh/month
- Energy per piece improved by 15% in 1 year
- Got recognition in buyer audit (Higg Index scoring improved)
Case Study 3: Dyeing Unit in Savar (Factory under PaCT)
Factory Profile:
- Type: Knit dyeing and finishing
- Process: Steam-intensive (dyeing machines, drying, calendaring)
- Known for: High thermal energy use
EMS Implementation:
- Received technical support from IFC PaCT
- Conducted full thermal energy audit
- Installed condensate recovery system and automated boiler control
- Mapped process flow and energy balance (steam use per machine)
Results:
- Thermal energy consumption reduced by 22%
- Payback for condensate system: 14 months
- ISO 50001 pre-audit readiness completed in under 1 year
Case Study 4: Mid-Size Factory in India (For Regional Context)
Factory Profile:
- Country: India (Tirupur)
- Size: ~800 workers, mostly T-shirts and polos
- EMS Starting Point: Fragmented, no real tracking
EMS Actions:
- Partnered with an energy consultant to run a 3-month pilot
- Used Google Sheets + low-cost IoT meters for machine-level tracking
- Installed motion sensors in warehouses and admin blocks
- Shared energy dashboards on floor noticeboards weekly
Outcomes:
- Employee behavior improved significantly (machines turned off during idle)
- Monthly savings of INR 75,000 (~$900)
- Energy cost/unit reduced by 11%
Key Takeaways from All Case Studies
| Lesson | Impact |
| Start small with awareness and quick wins | ~5–10% cost savings possible |
| Train internal staff as Energy Champions | Reduces dependency on consultants |
| Use submetering on key areas (boiler, compressor) | Enables focused improvements |
| Involve production teams and operators | Drives behavior-based savings |
| Combine EMS with compliance tools (e.g., Higg Index) | Enhances buyer trust & competitiveness |
EMS Tools & Technologies for Mid-Sized Factories
Many garment factories assume that Energy Management Systems (EMS) require expensive, sophisticated software. That’s a myth.
In reality, EMS tools can range from manual tracking sheets to smart IoT solutions, depending on your budget, infrastructure, and goals. Below is a breakdown of tools and technologies tailored for mid-sized garment factories.
Entry-Level Tools (Low Cost / No Tech)
Perfect for factories starting from scratch or piloting EMS without heavy investment.
Tools:
- Excel/Google Sheets: For daily, weekly, or monthly energy data entry
- Printed tracking logbooks: For operators to manually record machine on/off times
- Wall charts: To show energy trends and daily consumption
Use Cases:
- Monthly utility bill tracking
- Energy per piece (EnPI) monitoring
- Comparing departments (e.g., Cutting vs Sewing)
Benefits:
- No hardware or software needed
- Great for staff engagement
- Customizable to your processes
Intermediate Tools (Submetering + Software Dashboards)
For factories ready to go beyond manual data and focus on real-time or semi-automated monitoring.
Tools:
- Digital Submeters: For diesel generators, compressors, boilers, sewing lines
- Portable data loggers: To monitor load, voltage, current over time
- Energy dashboards: Using Power BI, Google Data Studio, or open-source tools
Use Cases:
- Monitoring steam usage per dyeing machine
- Tracking generator efficiency (kWh/Liter)
- Identifying energy waste patterns (e.g., nighttime consumption)
Benefits:
- Real-time insights
- Easier reporting for management and buyer audits
- Improved accountability across departments
Advanced Tools (Automation & IoT-Enabled EMS)
Ideal for forward-thinking factories aiming for long-term EMS optimization and compliance with ISO 50001 or Higg FEM Level 3.
Tools & Systems:
- Building Management Systems (BMS)
- IoT-enabled EMS platforms (e.g., EnMS by GIZ, Higg-integrated tools)
- SCADA Systems: Supervisory control with real-time feedback
- Energy modeling software: For predictive analysis (e.g., RETScreen, EnergyPlus)
Use Cases:
- Automated alerts for abnormal energy spikes
- Boiler and chiller automation based on load
- Centralized EMS reporting across multiple factory locations
Benefits:
- Deep process optimization
- Faster ROI tracking and ISO audit preparation
- Full integration with CSR and compliance platforms
Tools Recommended by Buyers or Local Initiatives
Some tools are recommended (and partially funded) by industry programs in Bangladesh:
| Tool / Program | Provided By | Usage |
| EMS Toolkit (PaCT) | IFC | Excel-based tracking & SOP templates |
| BGMEA Energy Portal | BGMEA/SREDA | Energy benchmarking & training |
| GIZ EnMS Web Platform | GIZ | Online EMS for monitoring & reporting |
| IoT Starter Kits | Private suppliers (e.g., EnerGaia, SmartEnMS) | Plug-and-play metering kits |
How to Choose the Right Tools
| Factory Readiness | Recommended Tools |
| Just starting | Excel sheets, logbooks, wall dashboards |
| Low investment budget | Submeters + Google Data Studio |
| Buyer pressure present | GIZ/PaCT tools + Higg EnPI tracking |
| Medium to high technical skill | Open-source IoT platforms + Power BI |
| ISO 50001 ambitions | SCADA + full automation |
Common Mistakes to Avoid When Implementing EMS
Implementing an Energy Management System (EMS) in a mid-sized garment factory can be a game-changer—but only if done right. Many factories start with good intentions but stumble due to avoidable mistakes.
Here’s a breakdown of the most common EMS mistakes and how to prevent them—so your factory doesn’t waste time, money, or momentum.
Starting Without a Clear Goal
Mistake:
- Jumping into EMS just to “reduce bills” without defining what success looks like.
Impact:
- Disorganized efforts, poor team motivation, and no measurable outcomes.
Solution:
Define specific targets:
- Reduce electricity cost by 10%
- Lower boiler fuel use by 15%
- Track energy per piece weekly
Overcomplicating in the Beginning
Mistake:
- Trying to install expensive meters or software right away without team readiness.
Impact:
- Team confusion, abandoned tools, or wasted investment.
Solution:
- Start with simple tracking, like manual readings or basic Excel dashboards.
- Scale gradually as your team builds comfort.
Ignoring the Production Team
Mistake:
- Treating EMS as a job only for engineering or utility departments.
Impact:
- Operators leave machines running, energy-saving protocols get ignored.
Solution:
- Involve sewing, finishing, and admin staff in EMS meetings.
- Set floor-wise targets (e.g., reduce idle-time power use).
- Use visual reminders like “Turn Off When Not in Use” signs.
Not Assigning Clear Responsibility
Mistake:
- No one owns EMS tracking, so no one feels accountable.
Impact:
- Inconsistent data, no follow-up on energy spikes or leaks.
Solution:
- Assign an Energy Champion (could be a junior engineer or quality staff).
- Include EMS KPIs in job descriptions.
Skipping Staff Training
Mistake:
- Installing tools without training people how to use them.
Impact:
- Tools are ignored or misused, reports become inaccurate.
Solution:
- Run monthly refreshers on EMS roles and usage.
- Use short videos or posters to reinforce concepts.
Not Monitoring Trends Over Time
Mistake:
- Focusing only on monthly bills without analyzing trends or anomalies.
Impact:
- Missed chances to catch slow leaks, inefficient machines, or nighttime wastage.
Solution:
- Track weekly and monthly trends (EnPI, machine idle time, etc.)
- Investigate unusual spikes or dips immediately.
Focusing Only on Electricity
Mistake:
- Ignoring other major energy sources like steam, diesel, LPG, or CNG.
Impact:
- Partial EMS that misses bigger saving opportunities in the boiler room or generator.
Solution:
- Include all energy sources in your EMS scope.
- Boiler and compressor efficiency often hide the biggest savings.
Treating EMS as a One-Time Project
Mistake:
- Running EMS for a few months and then forgetting about it.
Impact:
- Gains are lost, staff revert to old habits.
Solution:
- Make EMS part of your monthly management meeting agenda.
- Tie EMS performance to production bonuses or department KPIs.
Summary Table: EMS Mistakes and Fixes
| Mistake | Why It Fails | How to Fix It |
| No clear goals | Unfocused efforts | Set measurable energy targets |
| Going too high-tech too fast | Staff won’t use tools | Start small and build |
| Leaving out production staff | No behavior change | Train & involve all departments |
| No responsible person | No accountability | Assign an Energy Champion |
| No training | Tools underused | Monthly refreshers and visual SOPs |
| No trend tracking | Missed waste | Monitor weekly/monthly EnPIs |
| Focusing only on electricity | Misses thermal savings | Include boilers, gensets, LPG |
| EMS not continuous | Temporary impact | Integrate into factory systems |
How to Get Started with EMS in Your Factory
Starting an Energy Management System (EMS) in a mid-size garment factory doesn’t have to be expensive, complex, or overwhelming. The key is to start simple, stay consistent, and build momentum step by step.
Here’s a realistic roadmap to help your factory kick off EMS—whether you’re starting from scratch or formalizing scattered energy efforts.
Step 1: Get Management Buy-In
Why: Without support from factory leadership, EMS efforts won’t last.
Present a simple case:
- Share monthly utility costs
- Highlight wastage (idle machines, overused boilers)
- Show how saving 10% = increased profits
Suggest a pilot EMS for one department or utility (e.g., sewing floor electricity or boiler fuel).
Step 2: Form an EMS Core Team
Who to include:
- Utility Engineer
- Maintenance Supervisor
- Production Floor In-Charge
- Quality or IE (Industrial Engineering) staff
- Admin/Compliance representative
Step 3: Choose Your First Focus Area
Start with the biggest energy use or easiest savings:
| Option | Why Start Here |
| Electricity (lighting/machines) | Easy to track and switch off |
| Boiler Fuel (LPG, diesel, natural gas) | High cost, often inefficient |
| Generator Diesel | Easy metering, visible run hours |
| Idle Machine Time | Behavioral control, zero investment |
Step 4: Set Simple KPIs and Targets
Example KPIs:
- Energy per piece (kWh or BDT per piece)
- Boiler fuel per kg of dyeing
- Idle machine hours/day
Set SMART targets:
- “Reduce sewing floor electricity by 8% in 3 months”
- “Cut boiler fuel use by 10% in 6 months”
Step 5: Track and Record Data
Start with basic tools:
- Excel or Google Sheets
- Paper logbooks
- Weekly whiteboard updates
- PaCT or GIZ EMS templates (free)
Step 6: Analyze & Take Action
Don’t just collect data—use it!
- Investigate unexpected spikes
- Identify machines wasting energy
- Fix leaks or over-pressure in boilers/air compressors
- Switch off idle machines during breaks
- Reward teams for achieving energy targets.
Step 7: Expand Gradually
Once the first pilot works:
- Add more departments (finishing, washing, office)
- Introduce submeters
- Automate readings
- Consider ISO 50001 steps if needed
Bonus: Free EMS Starter Kits & Training in Bangladesh
Organizations offering support:
| Program | What They Offer | How to Access |
| PaCT (IFC) | EMS tools, training, assessments | www.textilepact.net |
| GIZ EnMS | Online EMS software + mentoring | Via GIZ/BGMEA collaboration |
| BGMEA Energy Cell | Technical training, support | Contact BGMEA for current programs |
| SREDA | Government policy support, tools | www.sreda.gov.bd |
Conclusion: EMS is the Smart Move for Garment Factories
Energy Management Systems (EMS) are no longer optional—they’re essential for mid-size garment factories aiming to stay competitive in a global market.
By adopting EMS, your factory can:
- Cut energy waste and reduce costs
- Improve operational efficiency
- Meet buyer and compliance requirements
- Increase your environmental credibility
Energy isn’t just a utility cost. It’s a profit lever.
Frequently Asked Questions (FAQs)
Here are the most common questions factories ask when starting their EMS journey:
Q1: What is an Energy Management System (EMS) in a garments factory?
A: An EMS is a structured way to monitor, track, and reduce energy use in a factory by setting goals, collecting data, and taking action regularly.
Q2: Is EMS suitable for small or mid-size factories, or only for large ones?
A: EMS is highly effective for small and mid-size factories. In fact, smaller units often see quicker results because changes can be implemented faster.
Q3: Do we need expensive meters or software to start EMS?
A: No. You can start with manual data tracking in Excel, whiteboards, or logbooks. Digital tools can be added later as your system matures.
Q4: How long does it take to see energy savings after EMS implementation?
A: Many factories see measurable savings within 3–6 months if they track and act consistently.
Q5: What kind of staff training is needed for EMS?
A: Basic training on turning off idle machines, checking boiler pressure, and tracking energy data. It’s more about behavior than technical skills.
Q6: How do we calculate energy per piece?
A: Divide your total energy use (in kWh or cost) by the total garments produced in the same period. This gives a useful benchmark.
Q7: Can EMS help with buyer compliance or certification?
A: Yes. Many buyers now ask for EMS programs or energy KPIs. EMS also supports ISO 14001, Higg Index, and even ISO 50001 readiness.
