Phu Dong Textile Co., Ltd is founded in 2006, specializes in manufacturing grey fabric and interlocked and sized fabric according to the demand of markets. Products are mostly for domestic markets such as Central region, Hanoi, and Ho Chi Minh City, 40% of the products are exported to European, Korean and Japanese markets. The capacity of plants is 5,000,000 m of sizing and warping per year, and 2/ 1,000,000 m of raw fabric per year

Before applying CP, the serious problem of the company is pollution caused by wastewater and exhaust fumes. Wastewater of company has exceeding the limit values in the standard TCVN 5945-2005, (COD (140,5mg/l) was exceeded 2,8 times, BOD (73mg/l) was exceeded 2,43 times and TSS (132mg/l) was exceeded 2,64 times. Company’s exhaust fumes generated from fuel burning and boiler operation. CO content (1.264mg/m3) in exhaust gas was exceeded 1.2 times in comparison with the limit value in National Standard. For solving these problems, in 2009, the factory received the support from the Ministry of Industry and Trade via the Cleaner Production in Industry Component (CPI) to conduct Cleaner Production Assessment and Application.

Under the MOIT support, in 2009, the company had implemented CP assessment. In the 1st phase (from July 2009 to February 2010), the Company established a CP team led by Mr. Doan Xuan Tinh –Director of the company and other 6 members to assess the whole production line. The Team has conducted a walk-through assessment on the tea production line at place. After the assessment and identification of waste streams, the Team has conducted mass and energy balances for the whole production line. All collected data have been used to analyze and identify Cleaner Production options for each production step

After conducting CPA and identifying improvement options, the Company has carried out 9 no-cost and low-cost options with a total budget of VND 50 millions. Such application has reduced material and electricity specific consumption to 20% and 3.4% respectively and saved 230 million dong. In the second phase (from March 2010), the Company has actively implemented high-investment options to improve the product quality and solve completely the environmental issues at place and received CPI’s support (2 billion dong) to install by a 3pass- horizontal boiler, update and repair sizing machine, install new automatic splicing machine, install dust suction and filtering system to improve environment working. Benefits from those solutions are 1.2 billion dong by reducing raw material consumption and reducing environment treatment cost.

Particular benefits derived from Cleaner Production are as follows:

Technical benefit	Economic benefit	Environmental benefit
Phase 1
Reduction of 20% specific consumption of material	Saving of 1 billion dong	Significantly improve the working environment of the factory workers
Reduction of 3.4% specific consumption of electricity
Phase 2
Reduction of 37,8% specific consumption of material	Saving of 1,2 billion dong	Reduction of 130 tons of CO2/year to environment Reduction of 1.5 tons of residual yarn, waste yarn/year

Typical Cleaner Production options of the Company are as follows:

No.	CP Option	Investment	Performance	CP technique
1	Train to improve skill of the workers as well as change their working attitude for reducing the residue/end cut yarn	No cost	Reduction of solid waste	GH
2	Classify fuel wood as suitable dimension    No cost	No cost	Saving of 220 million dong Reduction of 20% of fuel wood consumption Reduction of air emission	GH
3	Insulate the heat (insulation for 20m gas cylinder, insulation by valves where insulation layer broken)	10 million dong		GH
4	Immediately fix steam leakages, replace broken valves	2 million dong		GH
5	Replace motor- beltings, replace ball-bearings at the two air compressors	35 million dong	Reduction of 3,4% electricity specific consumption Saving 10,16 million dong and reduction GHG emission	GH
6	Install transparency sheets at ceiling of the work shop for using natural light	2.4 million dong		EM
7	Replace 40 filament lamps of 40W by 10 compact ones of  15W	0.6 million dong		EM
8	Install by a 3 pass- horizontal boiler     1,4 billion dong	1.4 billion dong	Saving of  508 million dong/year; reduction of 1,700 m3 of wood /year, 42 tons of coal/year, reduction of 3,000 tons of CO2/year	EM
9	Install sizing machine	3,5 billion dong	Saving up 1.3 billion dong/year Reduction of 738 kg of solid waste Reduction of 30% of size chemicals Reduction of 30% of total amount of water use for sizing process	EM
10	Install new automatic splicing machine (take only 30seconds for every splicing, reducing losses	600 million dong	Saving of 232 million dong/year	TC

Remarks: GH: Good Housekeeping; EC: Equipment Change, TC: Technology change

Perceiving the benefits from CP application, the factory insisted to maintain the CP team activities and integrate CP in the general management system at place. In order to facilitate CP application, a simple environmental management system has been developed. The factory has also set up environmental policy, whereby it is requested that the environmental protection law and other regulations should be followed strictly, ensuring the sustainable development of the company and reducing waste emission sources. The factory has integrated process management system with the environmental management system, therefore, energy and material consumption is monitored at the same time with the monitoring of pollutant parameters in the waste streams. A sample system and legal procedures are built and applied for environment data collection, checking, classification and data analysis.

An environmental monitoring plan has been initiated. The aim of the plan is to monitor significant improvements from applying CP or to adjust if there is any reduction in environmental benefits. Environment monitoring system includes monitoring air quality and wastewater.

CP not only brings about benefits from energy saving, emission minimization, reduced water consumption, but also helps the Company increase production, improve product quality, and prove prestige. The implemented CP options at the Company are a typical case study for enterprises in the sector of textile production in Vietnam./.