Case study: DaGama

Da Gama Textiles is a large manufacturer of bleached, dyed and printed fabrics. The company purchases raw fabric and also weaves roughly 50% of its fabric requirements on site. The company produces 1.3-1.5 million metres of fabric per month and employs 600 people. The manufacturing facilities comprise a large single textile mill in Zwelitsha, King Williamstown, in the Eastern Cape. Da Gama’s products are distributed to the southern African region to more than 200 individual customers.

Da Gama’s Zwelitsha textile mill was constructed in 1946, and its steam system is dated. The company employs a diverse mix of manufacturing technologies including weaving, washing, bleaching, dyeing, printing, heat treatments and others, many of which require steam for their operation. While most of the investments made by Da Gama since the original assessment have been in the area of production capacity, these newer technologies have nevertheless had some flow-through benefits for steam system efficiency.
 
Key Findings
Over the period 2012-2015, seven projects were undertaken, resulting in a total energy saving of 40 678 869 kWh, valued at R 9 492 000. With an investment of R 1 320 000, the payback was 0.14 years. A reduction of 10 431 tonnes CO2 was achieved.