Global Textile Alliance business case
How Global Textile Alliance Saved €175,000 with Data-Driven Energy Management
In industry, "small" efficiency gains are rarely truly small. A few percent less standby consumption, smarter compressed air control, or better-tuned steam pressure… It quickly adds up in euros and CO₂ impact.
Global Textile Alliance is a strong example of this: thanks to a series of optimizations driven by data and insights from Enprove, the company achieved a total cost saving of approximately €175,000.
Gaining control over the major consumers
The production environment of Global Textile Alliance (GTA) is extremely energy-intensive: the company knits and weaves mattress fabrics and finishes and dyes yarns for mattress and upholstery fabrics.
Two major consumers, or "big guzzlers," stand out in their processes. The weaving mill is mainly powered by compressed air, resulting in high electricity consumption. Additionally, the dyeing department uses steam dryers to generate heat, which also creates a significant energy demand.
Stricter regulations and increased compliance pressure
On top of that comes the reality of the energy transition. The sector is under increasing pressure to reduce gas consumption and lower CO₂ emissions (within the framework of EBO obligations).
This translates into concrete questions such as: is it worthwhile to install electric boilers? How do you handle obligations regarding rooftop PV installations, including the necessary stability studies? These are decisions that require expertise across multiple fields.
Measuring, analyzing, and targeted adjustment
Global Textile Alliance decided to involve Enprove because certain aspects were too specialized to cover internally. We have now been working closely together for ten years, with Enprove experts supporting them in energy plans and monitoring reports, specific calculations, and developing suitable measures. Our experts are also always available for questions regarding energy consumption and its impact.
Collecting data to understand what’s happening
Previously, nothing was actually measured, and the compressed air system was outdated. Therefore, we conducted a temporary measurement to map the actual consumption. These meters were connected to our Enelyzer software, allowing us to measure and monitor energy data. Based on this, reports were created and the information could be "sized." In plain language: not just collecting numbers, but being able to specifically see where heat was lost, when standby consumption occurred, and where leaks were present.
Based on this, reports were prepared and the information could be "quantified." In simple terms: not just collecting numbers, but being able to clearly identify where heat was lost, when standby consumption occurred, and where leaks were present.
Where are the deviations and opportunities?
The data revealed, among other things, that the existing compressors’ switching was no longer aligned with consumption, causing the specific consumption to be higher than normal. Additionally, there was a relocation of the 10-bar compressed air network to a new site: based on actual consumption, it was now possible to make a well-founded estimate of how much heat recovery could be achieved.
Appropriate measures that truly deliver results
Based on all the insights, targeted actions followed. We critically reviewed supplier proposals for new compressors to ensure the solution matched actual consumption. We also advised investing in compressed air meters so that consumption could be monitored per department and leaks detected more quickly.
It was a significant investment, but one that Global Textile Alliance considers the right step: thanks to smart switching between pressure networks, the site became more flexible and compressor capacity could be better aligned with compressed air needs.
Small percentages add up to make a huge difference
Together with several additional optimizations, the result is clear: the processes are now significantly more energy-efficient. Global Textile Alliance reports a total cost saving of approximately €175,000. Here’s a summary of the "small" gains:
- 1.3% savings by reducing standby consumption
- 4% through steam optimization
- 4% through heat recovery
- 5% through compressed air optimization
- 3% through dryer optimization
All together, this naturally makes a huge difference in absolute numbers. This business case from Global Textile Alliance clearly shows how data-driven energy management can quickly pay for itself—even when significant investments are required.
Curious about where the (most profitable) levers are in your company? Feel free to get in touch; we’d be happy to explore it together—with a focus on payback time and IRR.