Pali's hand process and power process units use very different energy: which records matter for each?
A Pali power process unit burns about 5 to 7 t of pet coke a day and uses around 3,000 kWh, so its boiler fuel log decides its carbon. A hand process unit heats dye pots over wood or briquettes with little power, so the fuel type and weight matter more than the meter.
Two kinds of unit
- Power process: jet dyeing, stenters and boilers or thermopacks, mostly for man-made fibre. 40,000 to 50,000 metres a day.
- Hand process: fabric soaked and heated in pots over wood or briquettes, mostly manual. 10,000 to 15,000 metres a day.
- Most of the cluster's more than 350 member units are hand process.
- The whole cluster turned out about 55 lakh metres a day and used over 51 crore kWh in 2007-08.
Power process: what to keep
- Pet coke (residual pet coke) receipts and daily boiler feed, in tonnes. Units moved to it when Gujarat lignite stopped.
- Electricity bills: a typical unit used over 75,000 kWh a month.
- Generator diesel, if any.
- Metres or kg processed per day, from the dispatch register.
Hand process: what to keep
- Weight of wood, briquettes or coal bought, and which it was. Smaller units burn 1,000 to 1,500 kg a day.
- Wood and briquettes count as biogenic CO2, reported separately; coal counts in full.
- Printing units' power: 160 to 500 kWh a day.
- Metres processed, even if only from job cards.
Why the split matters to a buyer
A garment brand asking for kg CO2 per metre will get very different answers from the two kinds of unit. Report fuel by type, not as one fuel bill total, so a biogenic fire is not counted as coal.
One day in each kind of unit (estimate)
- Power process: 6 t pet coke x 3.17 = 19.0 t CO2, plus 3,000 kWh x 0.675 = 2.0 t
- 21.0 t / 45,000 metres = about 0.47 kg CO2 per metre
- Smaller unit on 1.25 t of coal: 1.25 x 1.76 = 2.2 t CO2 a day
- Same unit on 1.25 t of wood: fossil CO2 near zero; the wood's CO2 goes in a separate biogenic line
Daily quantities from BEE's Pali cluster manual (2007-09 data); pet coke and coal factors from IPCC 2006 and India's BUR-2. Your own logs replace them.
What Senseible does here
Senseible reads pet coke, coal and wood invoices by fuel type and keeps biogenic fuel on its own line, so your carbon number per metre separates the two.
Sources: BEE SME programme, Cluster manual: Pali textile cluster, IPCC 2006 Guidelines, Volume 2 Energy (fuel emission factors), CEA, CO2 Baseline Database for the Indian Power Sector (grid factor 0.675 kg CO2 per kWh, FY 2025-26), GHG Protocol Corporate Standard
Last reviewed 2026-10-31.