Energy Efficiency in The Food Processing and Garment Sector in Vietnam. Nguyen Dang Anh Thi, November 2012

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1 Energy Efficiency in The Food Processing and Garment Sector in Vietnam Nguyen Dang Anh Thi, November 2012

2 Agenda Vietnam Energy Efficiency Outlook & Potential Energy Saving. Energy consumption in food sector. Energy consumption in garment sector. Energy saving potential and business opportunities Business opportunities in energy efficiency services Business opportunities in energy efficiency products Market entry strategy for German companies. Case studies

3 Vietnam s Energy Efficiency Outlook In 2011, total final energy consumption in Vietnam was about 85.6 billion kwh, increasing 400% compared to energy consumption in Vietnam emission increased 376% from 5.8 million metric tons of carbon in 1990 to 27.8 tons in 2005, ranking first in CO2 emission worldwide between 1990 and Energy consumption in Vietnam is forecast at 451TWh by 2030 of which energy consumption of industry sector accounts for more than 50% In the last five years, Vietnam has started to import steam coal and oil products for its energy need. Continued GDP growth, increased foreign investment, and industrial growth are expected to triple energy demand in the next decade In order to meet the growing power demands and to ensure a sustainable economic growth, Vietnam indeed needs to invest in energy efficiency. The law on energy efficiency and conservation took effect in 2011 requiring major energy users to apply energy management systems => creating a concrete legal framework for energy efficiency and conservation activities.

4 Nominal GDP(US$ billion) and Population (Million) GDP Population Source: World Bank Economic Outlook Database

5 Vietnam Energy Consumption vs. Other Asian Source: Market Potential Energy In Southeast Asia, 2011, Roland Berger

6 Vietnam s Share of Energy Consumption by Sector 100% 80% 15% 17% 17% 16% 16% 60% 30% 29% 27% 25% 23% Agricutural Commercal & Services 40% Residential & Others Transportation 20% 47% 47% 49% 53% 55% Industry 0% Source: APEC. Peer review on energy efficiency in Viet Nam, 2009

7 Gross Industrial Output In Vietnam Industry Source: Subtracted from Vietnam - Expanding Opportunities for Energy Efficiency. World Bank, 2010

8 Potential Energy Saving By Sectors Source: Statistics data from Vietnam National Energy Efficiency Program, 2000

9 Energy Consumption in Food Processing Sector Food sector overview Vietnam s food-processing industry comprises around 260 seafood-processing plants (mainly for export), 24 slaughter houses and meat-processing plants, 160 beverage plants, 65 fruit- and vegetable-processing plants, 27 plants manufacturing instant noodles and 23 confectionery manufacturers. Common types of energy used in the sector is electricity and fuel, of which electricity is consumed the most. Equipment that consumes much energy include: HVAC (heating, ventilation, and air conditioning), freezing machine, ice maker, cold storage, pumps, fans and other electrical motors. A majority of Small to Medium Enterprises (SMEs) is using outdated and inefficient energy equipments, either the boiler, heater, refrigerator, or lighting system such as high-pressure mercury lamp, incandescent and T10 fluorescent light bulbs. Many steamers have leaking issue.

10 Energy Consumption in Food Processing Sector (cont.) Energy Consumption in Food Proceeding Sector Survey conducted for 60 food processing SMEs Oil 29% Water 5% Electricity 45% Coal 21% Source: MEET-BIS

11 Energy Consumption in Garment Sector Garment sector overview Garment industry is a key sector and the largest employing sector. There are about 2400 textile and garment manufactures in Vietnam that employs almost 2 million people, of which there are about 1500 garment companies. Vietnam s textile and garment industry earned about 15.6 billion US$ export turnover in 2011 and currently accounts for 2.5% of the total global garment market share and is the fifth largest textile and garment supplier in the world Energy and water cost at Vietnamese garment companies is higher compared to other Asian countries. Energy cost to produce same products is times higher than that in Thailand, China, Malaysia. Water amount used in dyeing is 3 times higher than that in Japans Energy waste is up to 30% due to old technologies and outdated energy management systems. Approximately 50% of the equipment of garment industry of Vietnam has been used for over 20 years

12 Energy Consumption in Garment Sector (cont) Energy Consumptions of Equipment in Garment Sector compressed air & fan system, 9% Others; 7% Lighting; 22% Machinery; 62% Source: RCEE-NIRAS

13 Energy Saving Potential & Business Opportunity Food Sector Energy saving potential for food processing industry is up to 20% EE motors and variable speed drive (VSD) are promising products. The market size for EE lighting and EE equipment such as freezing machine, ice making machine, boiler ; insulation materials; inverter; heat pump; solar water heater are expected to be high. Garment Sector Energy saving potential for garment industry is up to 30% Energy cost accounts for 10-15% of production cost whereas energy waste is up 20-32% due to old technologies and outdated energy management systems. EE motors and variable speed drives are promising products as SMEs are willing to invest. The sewing saver also has a lot of potential

14 Business Opportunity in Energy Efficiency Services Capacity building on energy efficiency ISO50001 s related services Energy audit Energy management system software & hardware ESCO business: such as steam supply service with boiler using biomass Financial services

15 Business Opportunity in Energy Efficiency Products Energy saving up to Energy saving Ventilation Fans Fluorescent lamps Energy saving up to Energy saving Electricity management system Source: Meet-Bis Inverter

16 Business Opportunity in Energy Efficiency Products (cont.) Energy saving up to Energy saving up to Solar Water Heater Sewsaver fuel saving to Fuel saving Boiler System Heat pump Source: Meet-Bis

17 Strategy for German companies to approach potential enterprises in Food and Garment sectors Initiate pilot projects Implement pilot projects with food processing or garment SMEs to demonstrate the energy reduction potential for EE products Move towards an integrated value chain approach Demand identification: undertake auditing & energy consulting services Sales of products (core business): provide customized solutions Evaluation & Investment: build up own internal financing capabilities Delivery & Installation: improve and upgrade existing technical skills and capabilities Long term O&M: conduct regular technical reviews to optimize solutions and establish long-term relationships with clients

18 Strategy for German companies to approach potential enterprises in Food and Garment sectors (cont.) Develop innovative financing vehicles for EE projects Meet regularly with the banking community to build up their technical expertise in EE project financing. Increase awareness of EE and enhance professionalism of the industry Initiate collaboration with governments to organize conferences and industry events to share best practices and exchange positive experiences. Train sales staff at local dealers on technical features of EE projects

19 Case Study: Energy Saving at Hung Long Garment & Service JSC Company Overview Hung Long Garment & Services (Hung Long) was established in 2001 with 540 workers for the start. Over 10 years of operation and development, Hung Long now has over 2400 workers with 29 production lines in 10 factories. Its products are mainly exported to USA (70%), Europe (10%), Japan (5%), Korea (5%), and others (10%) The company s power consumption is very large, about 270,000 kwh/month, in which lighting systems consumes the most with more than 5400 kinds of bulbs Energy Saving at Hung Long Installed 500 power-saving devices for sewing machine system, saving 12.5% on energy cost Installed condensate recovery pump in the boiler, saving 25% on fuel costs

20 Case Study: Energy Saving at Hung Long Garment & Service JSC (Cont.) Energy Saving at Hung Long (cont.) Installed elevator system integrated inverter that helps to reduce energy costs by 15% for the elevator system Invested in 2900 sets of T8 fluorescent lamps with electronic ballasts, saving 18% energy costs for lighting. Replaced 900 sets of T10 to T5, saving 25% energy cost for lighting Outputs from Applying Energy Efficiency Total energy cost reduces 21%, from $180,000/year to $142,000/year From electrical energy saving: reduced 100 CO 2e /year From fuel energy saving: reduced 250 CO 2e /year

21 Case Study: Energy Saving at Investment Commerce Fisheries Corporation Company Overview Founded in 1999, Investment Commerce Fisheries Corporation (Incomfish) specializes in frozen seafood processing with a designed capacity of 15,000 MT a year. Its products are mainly exported to USA, Europe, and Japan Equipment used in Incomfish Three IQF lines with a combined capacity of 1,250 kg/hour Two Contact Freezers with a total capacity of 1,500 kg/batch Three Air-Blast Freezers with a capacity of 375 kg/bach/each An Air Blasting Freezer with a capacity of 2,500 kg/batch A Refrigeration system with a capacity of 3.7 Million kcal/hour Two Boilers with a total capacity of 1,000 kg/hour Two Power Generators with a total capacity of 2,500 KVA and other equipments

22 Case Study: Energy Saving at Investment Commerce Fisheries Corporation (Cont.) Energy Saving at Incomfish Installed 2 inverters for two water cooling pumps => energy saving of 12,000 kwh/year (energy saving 27%). Installed 2 inverters and 4 motor soft starters for 6 water pumps => energy saving of 13,500 kwh/year (energy saving 41%). Installed 2 inverters for 4 condenser fans => energy saving of 89,100 kwh/year (energy saving 30%). Installed solar water heater for the water supplied to the boiler => DO saving of 4%, pay back in 1.2 years. Other energy saving solutions applied: used T8 Fluorescent lamps with electronic ballasts to replace Incandescent and Halogen lamps, better demand side management etc.

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