# Presentation: 475113

## Utenos trikotažas: Practical Implications of Industrial Ecology 

- Company and main projects overview

**13 May, 2002**

## The Company

**Main projects**
**Conclusions**

**1**

## Key facts

**The largest knitwear producer in the Baltic States **
**About LTL 50 million investments during the last 4 years **
**modernising production equipment, technology, IT and facilities**
**BS EN ISO 9001:1994 certificate **
**ISO 14001:1996 certificate**
**Year 2001 **
**Sales LTL 127.7 million **
**Net profit LTL 12.3 million**
**Total 1400 employees end of period**

## Business philosophy

**The Company’s mission is *****to produce and swiftly deliver high quality knitwear underwear and outerwear at competitive prices***
**The business philosophy based on the credo of *****constant development***** **
**The main principles of the Company’s business philosophy**
**to be the leaders in the textile business in Lithuania and compete with the best producers in the world **
**sell products directly to retail chains **
**rapidly adopt the latest information technology**
**allocate funds to the improvement of working ****environment and production culture**
**protect health of employees as well as the environment**

## Total number of employees 1400 as at the end of 2001, average age approximately 38 years 
1152 women, 248 men
average length of employment at the Company about 16 years 
~ 10% hold a university degree

**1152 women, 248 men**
**average length of employment at the Company about 16 years **
**~ 10% hold a university degree**

**Employee statistics**

## Sales

**In 2001 export made up 88 per cent of total sales**
**Strong competitive position versus Asian producers**
**good price/quality balance**
**ability to respond quickly to changing fashion trends **
**proximity to Scandinavian and western European customers**

## The key markets are Western European countries

**H****igh-growth clothing and apparel retailers ****defined ****as target customer base**
**Fully positioned to supply high quality rapid-response products**

## Heavy investments

**Significant recent investments, LTL 50 million during last 5 years**
**increasing the capacities **
**ensuring appropriate quality level **
**changing the equipment to be more energy efficient **
**large-scale investments in information technology**

## Quality

**Modern system of quality control **
**based on precise planning and effective management of the production process**
**BS EN ISO 9001:1994 obtained In 1999**
**ISO 14001:1996 obtained in 2001**
**Production according to the Oeko-Tex 100 standard adopted**
**National Quality Award from the Quality Council and the Ministry of Economy in 1998 **
**ISO 9001:2000 intended to be obtained in 2002**

## The Company

**Main projects**
**Conclusions**

**2**

## Main projects

**Main goals****: energy savings and working conditions**** **
**Waste water heat recovery system**
**In ****1997 waste water heat recovery system ****by ****“Koenig”****, Switzerland, ****have been implemented.**
**Savings until now- 38200  Mwh heat energy and reused 433000 cub.m.of water**
**Printing technology**
**In 1998 printing screens production technology have been completely changed, no more solvents usage.**
**Natural gas**
**In 1999 own modern gas fired boiler house**** by “Bay”, Germany,**** have been built. Significant decrease in pollution of atmosphere as well as double decrease in the spending for energy.**
**In 1999 gas fired “Monti” dryer have been purchased**
**In 2001 gas fired “Bruckner” dryer have been purchased**

## Main projects: Constant improvement

**Water pump station**
**In 2000 automatic water pump station have been implemented**
**Ventilation and air conditioning stations with heat recovery units by “Luwa”, Switzerland**
**In 2001 implemented in dying and drying departments**
**In 2002 will be implemented in knitting department.**
**Insulation**
**In 2001 all main buildings have been insulated to save ****energy**
**Lightning**
**In 2002 the lighting will be changed in all departments **

## Main projects:  Modernisation of Dyeing department

**Dyeing equipment****s**
**Starting from 1999, ****6**** new dyeing equipment by “Thies”, Germany, have been installed**
**Dyeing recipes programs**
**In 2000, dyeing recipes program “ITMprocess” by “Datacolor”, Switzerland, have been installed**
**Production control and monitoring system**
**In 2000, control and monitoring system ”Orgatex” by “Setex”, Germany, have been implemented**
**Automatic dosing and preparation**** systems**
**In 2000-2001 the fully automatic solid and liquid chemicals dosing system and automatic dyestuff preparation system by “Color****S****ervice” , Italy, have been installed**

## Modernisation of Dyeing department: Results

**Capacity**
**Almost doubled dyeing capacity**
**Automati****s****ation of the process**
**To eliminate human errors and to ****d****ecrease the risk of unforeseen accidents**
**Energy resources, chemicals and dyestuff**
**Decrease the usage of chemicals and dyestuff 10-12****%****  per production unit**
**Quality**
**Monitor how the product parameters meet the standards**
**Pollution**
**Decrease the pollution of air and water **

## Results: Water consumption

**Reduction from the heat recovery **
**Reduction from dyei****n****g department **
**Total savings LTL 0,4 million**

## Results: Electricity consumption

**Lighting reconstruction**
**Investment o the new equipment **
**Frequency converters**
**Total savings LTL 1 million**

## Results: Steam consumption

**Heat recovery system**
**Own boiler house**
**Modernisation of dyeing department**
**Total savings LTL 4 million**

## Other projects: ISO 14001

**Obtained in 2001.**
**Acoording to ISO 14001 policy, w****e undertake the following obligations:****  **
**to achieve continual improvement of environmental protection,**** **
**production of safe and environmental products****,**
**to reduce or eliminate the use of harmful materials and safety treat chemical substances,**
**to use energy and natural resources effectively and economically,**
**to reduce enviro****n****mental pollution and minimize waste materials,**** **
**to dispose of waste in an environmentally soun****d**** way**

## Other projects: Oeko-Tex 100

**Oeko-Tex 100 for fabrics:**
**The special quality requirements for yarn **
**The special requirements according TEGEWA to chemicals and dyestuff**
**The special requirements for auxiliary products**
**It means that products has no harmful substances and are safe to use, and that the entire production cycle has no negative impact on the enviro****n****ment and on the employees**** **
**The company also try to minimize the harmful effect of various production processes while designing new products**
**The company management sure that contamination should be prevented at is inception.**

## The Company

**Main projects**
**Conclusions**

**3**

## Conclusions

**Constant improvement as work concept has been proven **
**Energy savings remain critical due to forecasted increase in prices for energy resources**
**Environmental decisions give competitive advantages due to: **
**Decreasing energy costs,**
**Some clients, especially from Scandinavian countries, Switzerland and Germany****,**** require environmental friendly productions**** and sertification**