Brief overview of Gujarat BAT-reference document for the Textile sector: Niraj A. Shah

This webinar is the second in a series on industrial pollution prevention and control. Explore how Best Available Techniques (BAT) are being used to reduce industrial emissions in the textile and paper-pulp manufacturing sectors. Drawing on cross-country insights from OECD reports: Activity 6: Cross-Country analysis of selected sectors for comparison and Activity 7: Cross-Country Analysis of selected BREFs for Iron-Steel, Paper-Pulp and Waste incineration sectors, this webinar shed light on significant environmental challenges, highlighted shared and sector-specific emission control techniques and discussed the potential for harmonising BAT implementation globally. The findings are based on reviews of BREFs from the European Union, the United States, China, India, Korea, Japan and the World Bank.

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Niraj A. Shah
Head Office, Gujarat Pollution Control Board,
Gujarat State, India
03/07/2025
Brief overview of Gujarat BAT-Reference
Document (BREF) for Textile sector

2. Best Available Techniques (BAT)
Reference Document (BREF) for the Textiles Industry of Gujarat
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Introduction:
Comprehensiveguidelinedevelopedtopromoteenvironmentalprotection,
resourceefficiency,andsustainableproductioninGujarat’stextilesector–First
ofitskindeffortsinthecountry
DevelopedthroughacollaborativeprocessledbytheGujaratPollutionControl
Board(GPCB),involvingtheGujaratCleanerProductionCentre(GCPC),the
GermanFederalEnvironmentAgency(UBA),DeutscheGesellschaftfür
InternationaleZusammenarbeit(GIZ),industrystakeholders,NGOs,and
academia

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Joint Declaration of Intent signed
between UBA, GPCB and GIZ

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Methodology –Drawing up of BREF and its Quality Assurance
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Main Steps:
DefiningTORfortheauthor
Selectionofcompetentauthor
SearchforpossiblecompetentTWGmembers
FormationofTWG–itsactivationandcallforsuggestion
Kick-offmeeting:ToagreeonthescopeofBREF,toagreeonthedatatobe
collectedanditsformatetc..
Elaborationofthefirstformaldraft

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Methodology –Drawing up of BREF and its Quality Assurance
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Main Steps:
TWGcomments
Elaborationofthesecondformaldraft(optional)
TWGcomments(optional)
Finalmeeting
Finaldraft
Assess&reviewofdraftfinalBREFandResolvingsplitviews,ifany
ApprovalfromGoverningBoardofGPCB

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Purpose, Scope and Development Process
Clusters : Surat, Ahmedabad, Jetpur
Fabrics : Cotton, Polyester

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Launching of Gujarat Textile BREF
during the Vibrant Gujarat Global Summit 2024
64
BATs identified

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Best Available Techniques (BAT) –Identified (64)
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•General Management Techniques (05)
•Water Efficiency (10)
•Energy Efficiency (12)
•Process Optimization and Equipment Modification (11)
•Chemical Management (04)
•Pre-treatment
(09)
, Dyeing
(09)
, Printing
(04)
-(22)

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General Management Techniques
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Technique 1 Environnemental Management System
Technique 2 Resource Efficiency & Cleaner Production
Technique 3 Monitoring and control of operational parameters
Technique 4 Textile Production Planning & Scheduling
Technique 5 Certifications for Textile Industry
Overview on BATs from the Gujarat Textile
BREF

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Water Efficiency
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Technique 6 Condensate Recovery System
Technique 7 Utilization of Reverse Osmosis (RO) Plant’s Concentrate in washing application
Technique 8 Reuse of Cooling Water from Singeing Machines
Technique 9 Reuse of Post Bleaching Washes as Pre-Washes at Pre-treatment Machine
Technique 10 Reuse of Neutralization Wash from Mercerizer& CBR
Technique 11 Reuse of Vapor Condensate of Caustic Recovery Plant
Technique 12 Installation of Automatic Water Shut-Off Valves at Rotary and Flatbed Printing
Machines' Blanket Washing Water
Technique 13 Water Management through Water Monitoring
Technique 14 Partial/Full Wastewater Recovery in Rotary Relax Drum Washer
Technique 15 Installation of Squeeze Roller for liquid removal in the open width washing

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Energy Efficiency
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Technique 16 Energy efficiency plan and energy audits
Technique 17 Cogeneration with Low-Pressure Steam Turbine
Technique 18 Replace Reciprocating Compressor with Screw Compressor and Installation of Air Pressure
Monitoring to reduce air leakages and maintainoptimum pressure
Technique 19 Installation of Demand Controller and reduce contract demand
Technique 20 Installation of Variable Frequency Drive (VFD) and Soft Starter
Technique 21 Power Factor Correction
Technique 22 Self-Cleaning Heat Exchanger
Technique 23 Heat Recovery from Hot Wastewater in Continuous Process
Technique 24 Heat Recovery from Hot Wastewater in Jigger Dyeing Machine
Technique 25 Heat recovery from exhaust dyeing bath
Technique 26 Minimisationof energy consumption of stenter frames and dryers
Technique 27 Heat Recovery from Stenter Flue Gas

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Process Optimization and Equipment Modification
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Technique 28 Mechanical Dewatering of the Fabric
Technique 29 Replacement of Open Jigger with Closed Maxi Jigger
Technique 30 Installation of Temperature Controller in Processing Machine
Technique 31 Residual Moisture (Bound moisture) control in Drying Cylinders
Technique 32 Automated ColourKitchen for Dyeing Section
Technique 33 Automation in Jet Dyeing and Drum Machine
Technique 34 Airflow Jet Dyeing Machine
Technique 35 Cold Pad Batch Dyeing
Technique 36 Continuous Dyeing Processes (PAD-DRY and PAD-STEAM process)
Technique 37 Automated ColourKitchen for Printing Section
Technique 38 Digital Printing

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Chemical Management System
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Technique 39 Chemicals management system
Technique 40 Selection of process chemicals
Technique 41 Chemical Storage and Handling
Technique 42 Chemicals inventory

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Pre-treatment
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Technique 43 Minimisingsizing agent add-on by pre-wetting the warp yarns
Technique 44 Oxidative Desizing
Technique 45 Bio Scouring
Technique 46 Enzymatic washing to remove residual Hydrogen Peroxide after bleaching
Technique 47 Recovery of caustic soda used for mercerising
Technique 48 Replacing Acetic Acid with Mix. of Organic Acids (Formic Acid and Acetic Acid Solution)
during neutralization
Technique 49 Environment-friendly surfactants
Technique 50 Low emission preparation agents
Technique 51 Substitution of phosphorus or nitrogen containingcomplexing agents

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Dyeing
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Technique 52 Use of Glauber salt instead of common salt and its recovery and reuse
Technique 53 Replacing Soda Ash with Liq. Alkali Solution in dyeing liquor
Technique 54 Minimisationof dye liquor uptake in pad dyeing techniques
Technique 55 Exhaust dyeing of cellulosic fibreswith polyfunctional reactive dye stuffs
Technique 56 Optimized removal of unfixed dyestuff in reactive dyeing
Technique 57 Optimisedparameters for rinsing of cotton dyed with reactive dyes
Technique 58 Dispersing agents with higher bio-eliminability in dye formulations
Technique 59 Dyeing with levelling agents made from recycled vegetable oil
Technique 60 Environment-friendly reductive treatment post polyester dyeing

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Printing
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Technique 61 Volume minimisationof printing paste supply systems in rotary screen-printing machines
Technique 62 Recovery of residual printing paste in rotary screen printing
Technique 63 Reuse of residual printing pastes
Technique 64 Use of printing chemicals with improved environmental performance

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WorkShops and Programmes for Awarness –
Capacity Building
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IndustrialVisits
Consultativemeetingswithindustryassociations&industries
MeetingswithGPCBofficials-
Ms.BrigitteZietlowandMs.AlmutReichartfromtheGermanEnvironmentAgency
(UBA)visitedGPCBHeadOffice,Gujaratondt.15/01/2024alongwithGIZ-training
forofficersofBoardfordevelopingenvironmentalstandards,monitoringand
supervisionsystemsandinspectionprotocolsbasedontheGujaratBREF
documentforthetextilessector.

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WorkShops and Programmes for Awarness –
Capacity Building
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Understandinginternationalscenarioandsharingexperience–
OrganizationforOECD–GPCBworkshoponBATwithInternationalExperts
[November,26-27,2024]:Theworkshopentitled“CapacityBuildingonBAT”,.
TheeventfeaturedexpertpresentationsfromenvironmentalagenciesofGermany,Korea,theUnited
Kingdom,andtheUnitedStates,facilitatingrichcross-countryknowledgeexchangeonBAT.
Overahundreddelegatesparticipated,includingrepresentativesfromOECD,UBA,GIZ,CPCB,IRO-MoEFCC,
variousSPCBs,GCPC,OfficialsofGPCB,concernedindustryassociations,NGOs,andinternationalexperts.
DuringthesessionsGPCB’spioneeringlaunchofIndia’sfirstBREFdocumentforthetextilesectorandthe
initiationofasimilarinitiativeforthepaperrecyclingindustrywashighlighted.
AtechnicalsitevisittoArvindMills,Khatraj,GandhinagarofferedOECDofficialsvaluableinsightsintothe
real-timeapplicationofsustainableproductionpracticesandinnovativetechnologiesadoptedinthetextile
industry.

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WorkShops and Programmes for Awarness –Capacity Building
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WorkShops and Programmes for Awarness
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Bharat Tex 2024:
Bharat Tex 2024 Highlights
•Global textile mega event held from 26–29 February 2024, New
Delhi
•Organized by 11 Textile Export Promotion Councils, supported by
the Ministry of Textiles
On 27 February, GIZ hosted a panel on:
“Best Available Techniques (BAT) for Textile Industry: Enabling
Resource Efficiency and Environmental Compliance”
Focus on:
•Awareness of BREF/COINDS initiativeby CPCB
•Launch of BREF Documentby GPCBfor the textile sector
Emphasis on sustainabilityand environmental compliancein textiles

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Way forward for implementation of the Gujarat
Textile BREF
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Clusterwiseenvironmentclinics
Informationexchangebetweenindustries,awarenesssessionsbyIndustries
Associations
InventoryofalreadyimplementedBATs
MatrixofapplicabilityofBATs-Scale,CostandEnv.Benefits-Toprioritize
implementation
ConsultationwithindustriesonMatrix
PilotstudiesforshortlistedBATsinvolvingCapex

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Adoptenvironmentalmanagementsystems
Maintaininventoriesofinputs/outputs
Implementadvancedprocessmonitoringforbettercontrolandefficiency.
Useresource-efficienttechniques
Improvechemicalmanagementtominimizehazardousreleases.
Optimizewastewatertreatmentandreduceemissionstoairandwater
Key Recommendations and BAT Conclusions:
Impact and Use:
The BREF serves as a reference for regulators when setting consent conditions and provides a roadmap
for textile units of all sizes (small, medium, large) to enhance compliance and sustainability.
It supports Gujarat’s leadership in environmental governance
Adapt as a model for other sectors and regions

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